Hydra Millennium Plus Technical Manual: System Overview
Hydra Millennium Plus Technical Manual: System Overview
Hydra Millennium Plus Technical Manual: System Overview
Technical Manual
Pilot Chair
Megacon GFI
Cage TMS
Volume 1
System Overview
Revision Data
REV. DATE BY APRV’D REMARKS
A 12/01/2008 D. Brown M. Philip Original Document (Pilot Chair,
Megacon GFI, Cage-type TMS)
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
II
About This Guide
Before proceeding with the operation and maintenance of the Oceaneering International Millennium Plus ROV
system, it is highly recommended that those responsible first read and understand fully the information in this
section, which encompasses some important hazard warnings and recommendations.
Potential Hazards
The Millennium Plus ROV system is a useful tool for undersea operations, yet its utility is not without potential
hazards. If the system is not operated and managed carefully by responsible and qualified personnel, it can be
dangerous and even lethal to those individuals in its operating vicinity.
The Millennium Plus ROV system includes potentially lethal electric currents and hydraulic pressures which even
with the system powered down can cause injury or death to personnel in the vicinity. When performing system
maintenance, always adhere to lockout-tagout procedures and ensure that all energy sources are isolated and
stored energy is released.
Because the Millennium Plus ROV system contains fluids that when coming in contact with the skin can cause skin
irritations, always wear protective clothing and gloves when performing system maintenance. In addition, because
hydraulic components can be slippery, always wear protective footwear when handling these parts.
Section 1 – Introduction
Provides a brief functional description of the overall Millennium Plus ROV system.
Section 2 – Specifications
Includes the physical, electrical and hydraulic specifications for the Millennium Plus ROV system.
Section 3 - Console
Provides an overview of the Millennium Plus Console.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
III
Section 4 – Tether Management System (TMS)
Provides an overview of the Millennium Plus TMS.
Section 5 – Vehicle
Provides an overview of the Millennium Plus Vehicle.
Section 7 – Telemetry
Provides an overview of data flow within the Millennium Plus system.
Icon Description
Section Colors
Color
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
IV
Table of Contents
Millennium Plus System Overview
December 2008
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
V
6.0 Electrical Power Distribution...................................................................................................... 6-1
6.1 Overall Description of Electrical Power Distribution Components ........................................... 6-3
6.2 Millennium Plus Console ......................................................................................................... 6-7
6.3 Power Distribution Unit (PDU) ................................................................................................. 6-9
6.4 PDU Component Layout........................................................................................................ 6-12
6.5 GFI Ground Fault Monitoring/Interrupting.............................................................................. 6-13
6.6 System Transformers ............................................................................................................ 6-14
6.7 HPU Boost Transformer Housing and Termination J-Box ..................................................... 6-16
6.8 Winch Stationary J-Box ......................................................................................................... 6-18
6.9 Winch Slip-rings..................................................................................................................... 6-20
6.10 Winch Rotating J-Box .......................................................................................................... 6-22
6.11 Armored Lift Umbilical .......................................................................................................... 6-22
6.12 TMS Umbilical Termination Can .......................................................................................... 6-24
6.13 TMS Transformer Can ......................................................................................................... 6-25
6.14 TMS HPU............................................................................................................................. 6-26
6.15 TMS Sliprings ...................................................................................................................... 6-26
6.16 TMS Tether Termination Can (Rotating J-Box) .................................................................... 6-27
6.17 Tether ................................................................................................................................... 6-28
6.18 Vehicle Tether Termination Can ........................................................................................... 6-28
6.19 Vehicle Transformer Can ..................................................................................................... 6-29
6.20 Port/Starboard HPUs ........................................................................................................... 6-30
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
VI
Section 1:
Introduction
Introduction
Section Contents
1.0 Introduction...................................................................................................................................................1-1
Millennium Plus System Overview
1.0 Introduction
The Millennium Plus is a powerful remote work system which incorporates the latest in technology to improve
its performance and maintainability. It is a dual manipulator, 170 EHP Work Class ROV System. It employs a
microprocessor based telemetry system to minimize maintenance, decrease set up time, simplify troubleshooting,
and to provide more automatic control functions. Fiber optics are used as the primary transmission link for all video
signals between the Vehicle, TMS and the surface control console which provides the finest quality video available
in ROV technology.
The subsea Tether Management System (TMS) is used to deploy the Vehicle to the work site. The Vehicle remains
docked to the TMS until the desired water depth is reached at which time the Vehicle can leave the TMS and
maneuver in any direction up to the working length (up to 300 meters) of the lightweight tether. All power and control
for the vehicle is passed through the main opto-electromechanical umbilical, through the TMS, and into the tether.
TMS deployment of the Vehicle helps prevent umbilical entanglement and improves Vehicle performance. Vessel
motion effects and current drag on the main umbilical are transmitted to the TMS only, allowing the Vehicle to have
unimpeded excursions to the full working tether length. Also, due to the weight vs. drag ratio of the TMS, station
keeping of the Vehicle at depth in high current situations is greatly improved.
This manual is intended to provide the first-time user with an introduction to the main features of the Millennium Plus
system. It is not intended to be a detailed maintenance manual.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 1-1
Millennium Plus System Overview
1-2 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Section 2:
Specifications
Specifications
Section Contents
2.0 Specifications
The following specifications pertain to the Millennium Plus System.
Vehicle : 211KVA
Tether Management System : 105KVA
Control Container : 25kVA
Workshop Container : 25kVA
Launch and Recovery System (LARS) : Varies according to actual equipment used
Auxiliary Power Unit : 30kVA
Above figures are for a 60Hz supply. Values will be higher for a 50Hz supply.
2.2 Weights
Vehicle : 3,990 kg (8,800 lbs)
Tether Management System (Cage) : 3,538 kg (7,800 lbs)
Control Container : 8,000 kg (17,600 lbs)
Workshop Container : 6,000 kg (13,200 lbs)
Launch and Recovery System (LARS) : Varies according to actual equipment used
Auxiliary Power Unit : 4,500 kg (9,900 lbs)
2.3 Vehicle
Length : 3.45 m (137 inches)
Width : 1.52 m (60 in)
Height : 1.83 m (72 in)
Payload : 408 kg (900 lbs)
Thru frame lift : 2000 kg (4,400 lbs)
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Millennium Plus System Overview
Tether : 400 m (1312 ft), length × 30mm (1.18 in) diameter power
conductors
Optical fibers for data/video transmission
2-2 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Section 3:
Console
Console
Section Contents
3.0 Console
The Millennium Plus Control Console equipped with a Pilot Chair and Megacon GFM is depicted in Figure 1 below.
Marshall
Panasonic
Panasonic
tvone TASK
1T-C2-150
MENU ZOOM F REEZE F ADE KEY MI X/PIP AUTOSET STAND BY
altex
altex
altex
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-1
Millennium Plus System Overview
The Hydra™ Millennium Plus System Control Console is assembled from three individual console bays or equip-
ment racks that are manufactured using the industry standard 19” front and back openings. The standard is de-
signed to accept screw-in modular equipment that have a maximum internal width of 15.75 inches, with a front face
panel that is 19” inches wide.
Each assembly/module/tray/panel that is mounted in the console is measured vertically in ‘rack units or ‘U’ (one
unit/U = 1.75 inches high). Rack mountable equipment is found in many different heights, ranging from the smallest,
measuring 1U high up to the maximum rack height of 45U (78.75 inches) high. Fractional U sized equipment does
exist, but tends to be fairly uncommon.
Each of the individual consoles has a defined function and is outfitted with the equipment, trays and/or panels re-
quired for that function.
Consoles can be rearranged, modified, or eliminated to suit the operational needs or spaces that they are installed
in. The actual arrangement or equipment mix may vary somewhat from the Control Console pictured in Figure 1.
In addition to the console racks, another part of the system is the Pilot Chair, depicted in Figure 2. The Pilot Chair
provides manual controls for operation of the Vehicle and manipulators.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-2
Millennium Plus System Overview
MEGACON GFM
PANEL
The Pilot Console in Figure 3
Marshall shows a typical arrangement of
10.4” LCD equipment.
MONITORS Installed equipment can and
does vary between various
Marshall systems.
20” HD LCD
MONITOR
POWER TRAY
PULLOUT
KEYBOARD
TV ONE SCAN
tvone TASK MENU ZOOM F REEZE F ADE KEY MI X/PIP AUTOSET STANDBY
CONVERTER
1T-C2-150
altex
AUXILIARY COMPUTER
altex
WINCTAG COMPUTER
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3-3
Millennium Plus System Overview
The GFM/GFI system is designed to monitor high voltage circuits that can
pose a lethal hazard to personnel in fault conditions.
WARNING!!
Oceaneering Policy requires that no ROV system will be operated with a
non-functioning or bypassed GFM/GFI System.
Note: The names Ground Fault Monitoring (GFM) and Ground Fault Interrupting (GFI) are terms that have been
used interchangeably to mean the same thing. To some extent the terms are region specific; GFM will be
encountered more often in Europe/AME, while GFI is more common in the Americas, just be aware that the
two terms refer to the same process.
A ground fault, simply defined, is a fault or condition that establishes an electrical connection between a previously
isolated electrical circuit and chassis ground. As the Millennium Plus system uses 2300VAC electrical power for its
HPU motors and 1300VAC for Vehicle and Cage electronic systems, a ground fault can present a potentially lethal
situation for anyone working on the system.
The Ground Fault Monitor (GFM) system will constantly monitor the vehicle’s high voltage circuits for the presence
of a ground fault. If a fault develops, the GFM system will shut down the faulty circuit by de-energizing the AC supply
contactor and giving the operator a warning that there has been a fault detected on the circuit.
Marshall
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-4
Millennium Plus System Overview
The Megacon GFM used in Millennium Plus systems operates by impressing a small DC voltage on to a high
voltage AC circuit and monitoring for a flow of DC current between chassis ground and the circuit being monitored.
In normal conditions where no ground fault exists, current flow will be zero. As a ground fault develops, current
begins to flow and the meter will indicate the equivalent GF resistance between the circuit and chassis ground,
triggering an alarm and shutting down the 480VAC contactor supplying the step-up transformer.
The modules have two LEDS on their face to indicate their operational status:
• The ALARM LED (normally OFF) is red in color and will turn on when the circuit resistance drops below the
alarm trip point (adjustable on the back of the unit and normally set to 500kohms).
• The NORMAL LED (normally ON) is bi-colored and glows green when the circuit is above the warning trip point.
It will turn amber if the circuit resistance drops below the warning trip point (adjustable on the back of the module
and normally set to 1Mohm).
The higher the reading, the better, but typically 5MΩ or lower indicates a problem is developing. 500KΩ or less will
trip off the contactor and will remove power from the circuit.
Once tripped, the effected circuit cannot be re-enabled until the ground fault is removed or repaired.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-5
Millennium Plus System Overview
The Power Tray contains the system’s power on/off switches, AC current meters, and several power supplies.
The Power Tray itself can be extended from the Pilot Console in order to access the internal electrical/electronic
components.
The Pilot Console Power Tray contains the power on/off controls for
the Cage and Vehicle electrical systems and the HPU Power Packs.
WARNING!! When working on any of these systems, the main supply breaker for the
PDU must be Locked Out/ Tagged Out to protect personnel against the
accidental activation of these controls.
The Power Tray front panel contains three separate 0 to 500amp current meters. Each meter is marked with the
circuit that the meter monitors. Each meter is connected to a current transformer mounted in the PDU and monitors
a single phase of the 3Ø 480VAC input to each HPU boost transformer.
The front panel also contains several pushbutton switches with built-in indicators. These switches serve the following
functions:
• CONSOLE POWER - controls the electrical power to the Power Tray and contactor control power to the
power distribution unit (PDU). When turned off, this pushbutton will also de-energize any other enabled
power contactors that happen to be energized at the same time. Re-energizing the CONSOLE POWER
pushbutton will not re-energize the contactors; they must be re-energized individually.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-6
Millennium Plus System Overview
• CAGE ELX - controls electrical power to the TMS electronics and electrical power circuits.
• VEH ELX - controls the electrical power to the Vehicle electronics and electrical power circuits.
• CAGE MOTOR - controls the electrical power to the TMS Hydraulic Power Unit (HPU). This circuit is
interlocked with the Cage ELX circuit and cannot be turned on until Cage ELX is energized.
• AFT/PORT MOTOR - controls the electrical power to the Vehicle Aft HPU. This circuit is interlocked with the
Vehicle ELX circuit and cannot be turned on until Vehicle ELX is energized.
• FWD/STBD MOTOR - controls the electrical power to the Vehicle Forward HPU. This circuit is interlocked
with the Vehicle ELX circuit and cannot be turned on until Vehicle ELX is energized.
• CAGE HPU BYPASS – unmarked pushbutton located just above and to the right of the CAGE MOTOR
power pushbutton switch. Enables a hydraulic valve in the Cage rate valve pack, which is connected to the
hydraulic pump’s DFR control block. Enabling this valve before starting the HPU motor places the pump in
a reduced pressure state and reduces the possibility of damaging the HPU motor by stalling it on start up.
Also reduces the starting current draw of the motor.
• VEHICLE HPU BYPASS – unmarked pushbutton located just above and to the left of the VEHICLE MOTOR
power pushbutton switches. Enables a hydraulic valve in the Vehicle rate valve pack, which is connected
to the DFR control block of both hydraulic pumps. Enabling this valve before starting the HPU motor places
the pumps in a reduced pressure state and reduces the possibility of damaging the HPU motors by stalling
them on start up. Also reduces the starting current draw of the motors.
Note: The Power Tray HPU on/off buttons are marked as AFT/PORT and FWD/STBD to make the Power Tray
compatible with the other ROVs that may have different HPU arrangements and utilize this Power Tray in their
Console. Millennium HPUs are arranged in a forward/aft arrangement while ROVs such as the Magnum have
their HPUs arranged in a Port/Starboard configuration.
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3-7
Millennium Plus System Overview
The 17” Pilot’s monitor is the primary monitor used by the Pilot for operating the vehicle.
In addition to a selectable video image sent up from one of the vehicles cameras, the Pilot’s monitor can also present
the Pilot with a graphical overlay giving operational data that the Pilot requires for the operation of the vehicle.
The Pilot or the Navigator can switch any of the available video inputs to this monitor and can select any (or none)
of several possible graphic overlays as well; the combination used can vary with the Pilots personal tastes and/or
operational needs of the moment
Typical Pilots graphical overlays are shown below:
The graphics overlay provides the basic vehicle navigation information required by the pilot:
• Vehicle heading
• Vehicle depth
• Vehicle Altitude
• TMS heading
• TMS depth
• Amount of tether deployed
• Vehicle turns
• TMS turns
• Vehicle pitch/roll
• Status of autocontrollers
• Time/date
See the CTAG manual for more detailed information on the graphics overlays.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-8
Millennium Plus System Overview
3.1.4 Pilot PC
The Pilot PC is a standard rack-mountable computer. The purpose of the Pilot PC is to run Oceaneering’s Control,
Telemetry, and Graphics (CTAG) software program, which forms the heart of the Millennium Plus telemetry system.
This software operates within a Microsoft DOS operating system.
CTAG receives commands from the Pilot and transmits them to the TMS and Vehicle via serial communications
links. Navigational and diagnostic data from TMS and Vehicle is received via the same serial data links and displayed
for the Pilot.
Serial communications are handled by two Fastcom 8 cards inside the PC. Each card provides eight RS-232 serial
communications channels, which CTAG uses to communicate with the outside world (e.g. Console, TMS, Vehicle,
Aux PC, CTAG for Windows PC).
3.1.5 Aux PC
The Aux PC serves two functions; first, it provides a second independent, but synchronized copy of CTAG that
allows the Navigator to independently access the CTAG graphic displays. Running an independent copy of CTAG
provides the Navigator with access to the various soft switches, diagnostic and operating displays that the Pilot
sees, without having to disturb or distract the Pilot with graphic screen changes.
The Pilot and Aux PCs synchronize their data through a RS-232 link, using a Fastcom port on each PC.
Secondly, the Aux PC can also serve be re-configured as a replacement for the Pilot PC in the event that the Pilot
PC fails.
Operation of the system is not dependant on the Aux PC and the system will function without it.
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3-9
Millennium Plus System Overview
In order to enhance the software features and graphics available to the Pilot, a version of CTAG has been developed
that operates within a Windows operating system.
The CTAG for Windows (CFW) PC replaces the Aux PC in later models of Millennium Plus. It communicates with
DOS CTAG on the Pilot PC via RS-232 link. The CFW PC provides all the same functionality as the Aux PC it
replaces.
The CFW application will only run on the CFW PC. CTAG for DOS still runs on the Pilot PC and is still in control of
the telemetry system. CTAG for DOS does not require CFW to be running or even the CFW PC to be operational
in order for it to operate.
Should the CFW PC fail in operation, you will only lose your enhanced graphics display (shown on a separate
graphics monitor) and the Navigator’s ability to control CTAG for DOS.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
3-10
Millennium Plus System Overview
Vertical
Cage Paddle
Thruster (Not Visible)
Armrest
Cage Rate Hand
Adjustment
Camera Controller
OPAC
(Not Visible)
Touch
Trackball
Screen
Seat
Pilot Joystick
Adjustment
Footstool
Adjustment
Tether
Adjustment
Elevator Power
Supply
The Chair receives analog and digital commands from the Pilot via the following input devices:
• Analog and digital hardware input devices (e.g. joysticks and switches)
• Analog and digital controls on the touch screen monitor
The hardware input devices are monitored by an Oceaneering Power and Control (OPAC) digital acquisition device
in the chair itself. This device is a simple stack of circuit boards that multiplexes the analog and digital inputs and
sends them via RS-232 serial data link to the Pilot PC.
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3-11
Millennium Plus System Overview
The touch screen monitor is connected to its own PC that runs a custom Windows application. Inputs made via the
touch screen user interface are multiplexed by this application and sent via a second RS-232 serial data link to the
Pilot PC.
The power supply for the PC is normally mounted inside the Chair pedestal.
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3-12
Millennium Plus System Overview
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3-13
Millennium Plus System Overview
The joystick itself is used for controlling the magnitude and direction of Vehicle thrust. Moving the joystick forwards
and backwards controls fore and aft motion of the Vehicle. Moving it left and right controls lateral motion of the
Vehicle. Rotating the joystick controls the azimuth (turns) motion of the Vehicle.
The function of each control mounted on the joystick is as follows:
• Pan and Tilt (P&T) - Camera Pan and Tilt, a four way switch used to control the Vehicle’s camera pan and
tilt unit in the horizontal and vertical planes.
• Vertical Up/Down - A two direction linear control used to control the Vehicle’s vertical thrusters. The control
is pressure sensitive, the magnitude of pressure applied being directly proportional to the magnitude of
thrust commanded.
• Tether In/Out - A two-position switch, used to control the direction of tether taken in or paid out of the TMS.
• Close/Lock - A two-stage ‘trigger-type’ switch, which when depressed to the first stage will close the jaw on
the selected manipulator and if held for longer than a preset limit (usually 5 seconds) will apply the lock to
the jaw. Depressing the switch to the second stage will immediately lock the jaw.
• Jaw Open - A push button that will release the jaw lock and open the jaw.
• Thrust Limit Switch - a three-position switch that sets the Vehicle’s thruster power to one of three preset
levels.
The P&T switch will control one of two Vehicle-mounted cameras depending on the setting of the SWITCH P&T
button on the touch screen. When the button is OFF, the P&T switch controls the hydraulic pan and tilt unit on the
Vehicle. When the button is ON, the P&T switch controls the pan-and-tilt dome camera connected to the FO Can.
The thrust limit switch commands CTAG to apply one of three preset scaling factors for the joystick analog output
pots. The scaled value is transmitted to the thrusters rather than the actual pot values. The scaling factor on each
position of the switch is set in CTAG and can be changed to any value that the operator wants between the ranges
of 0 to 100% of full scale. Normally the three positions are set to be low-25%, med-50% and high-100% of full scale.
There are two input devices for controlling the Vehicle’s vertical position; the paddle joystick on the left armrest and
the vertical control on the Vehicle joystick. CTAG will recognize commands from either and the Pilot does not need
to select which device to use.
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3-14
Millennium Plus System Overview
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3-15
Millennium Plus System Overview
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3-16
Section 4:
Tether Management System (TMS)
Tether Management System (TMS)
Section Contents
There are several different types of TMS in use on Millennium Plus Vehicles throughout the world, and while
many of these systems have been manufactured by Oceaneering, a number of them have been built by other
manufactuers or have been heavily modified from their ‘as built’ condition.
Of the TMS types used on Millennium Plus systems, the Top Hat and Cage type TMS’ shown in Figure 13 and
Figure 14 are the most commonly used.
These two TMS’ share many of the same components, operate in a similar manner, and serve the same general
functions, but there are important physical differences between them.
This document is limited to discussing the Cage TMS constructed by Oceaneering International.
While the term “Cage” is often used to refer to any type of TMS, it can cause confusion to call every TMS a cage.
Therefore, this document will use either Cage TMS or Top Hat TMS when referring to a specific type of tether
management system.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-1
Millennium Plus System Overview
The term “Tether Management” refers to the ability of the Cage TMS to pay out or recover tether as commanded
by the Pilot, as well as the Cage TMS Tether Drive Mechanism’s ability to cleanly and evenly spool tether on/off the
Tether Drum.
Managing the flying tether is the primary reason that the TMS exists and while it is possible to free swim the Vehicle
and not use a TMS at all, there are a number of distinct advantages gained by using a TMS over a free-swimming
Vehicle:
• Acts as a clump weight for the Vehicle; allowing for a safer, quicker transit through the air/water interface
and a faster decent to the working depth.
• Allows for the use and management of a flying tether.
• Provides a mounting platform, and electrical and signal connections for external instruments.
• Additionally; the Cage TMS provides increased protection to the Vehicle during rough weather launches/
recoveries and provides a large area in which to mount tooling, recovery baskets or work packages.
4-2 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
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Millennium Plus System Overview
Tether Storage
Drum
Port
Thruster
Tether
Sheave Figure 16: Cage Type TMS
Assembly
Stbd/Aft Component View
Stbd Vehicle
Clamp
Hydraulic Reservoir
Level Sensor Vehicle Safety
Latch
Hydraulic
Reservoir
Starboard
Thruster
Pressure
Gauges
Figure 17: Cage Type TMS
Port/Aft Component View Umbilical Termination Proportional
Can Valve Pack
Rate Valve
Pack
Telemetry
Can
4-4 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
HP Filter
Transformer
Can
Tether/Umbilical
Termination Hydraulic Power
and Transformer Unit (HPU)
(UMB) Compensator
Transducer Can
The operator can pay out or recover lengths of tether as often as their operational needs dictate. The tether is
managed using the Cage TMS Tether Drive Mechanism to spool in/out tether from the Cage TMS Tether Storage
Drum.
Depending on the make and diameter of the tether in use, the lightweight flying tether will allow the Vehicle to make
excursions of 1800 feet (550 meters) or more from the Cage TMS.
Note: Both “Housing” and “Can” are widely used terms, referring to the container that encloses wiring, Fiber Optic
terminations, electronic components, mechanical assemblies, etc. Either term can be and has
been commonly used to refer to either an Oil-filled or a Pressure-resistant container. This document will use
the generally accepted names, but in an effort to reduce any possible confusion, will use “Oil-filled” or
“Pressure-tolerant” as required to clarify any ambiguous names.
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Millennium Plus System Overview
Electrical terminations, cables, sliprings, valve packs, motor windings, Fiber Optic connectors, and certain electronic
components will generally operate reliably in oil-filled environments.
Oil-filled housings also offer a substantial weight saving over pressure-tolerant Cans.
Compensation is a method used to prevent the ingress of water into the various oil-filled components of the Vehicle.
This is accomplished by completely filling them with oil and then using a compensator to maintain the oil at an
above-ambient pressure.
The compensator is a flexible rubber bladder that holds a volume of oil. When the compensator is expanded by
being filled with oil, it will maintain a positive oil pressure in the compensation circuit for as long as there is no oil lost
from the circuit. Should a leak develop, it will be the oil that leaks out, rather than the seawater leaking in.
Figure 19 shows a typical example of a termination bullet, although the actual version used depends on the type of
handling system used to deploy the ROV system.
4-6 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Fiber Optic
High Voltage
Umbilical Core from Couplers
Terminal Strips
Umbilical Bullet
Oil-Filled
Connection to
Sliprings
Water Alarm
FO Cables to
Cable Low Voltage
Telemetry Can
Terminal Strips
Figure 20: Umbilical Termination Can Figure 21: Umbilical Termination Can with
Cover Removed and Exploded View
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-7
Millennium Plus System Overview
Transformer Can
Terminal Strips
Figure 22: Transformer Can Figure 23: Transformer Can – Cover Removed
High Voltage
Terminal Strip
Terminal Strips
Figure 24: Tether Termination Can Figure 25: Tether Termination Can – Cover Removed
4-8 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The motor housing and the Pressure Balanced Oil-Filled (PBOF) connector
connecting the housing to the umbilical termination contain lethal high-
WARNING!! voltage electrical connections.
Always ensure that proper Lock Out / Tag Out (LOTO) procedures are
followed when working on the motor housing or the PBOF connectors.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-9
Millennium Plus System Overview
An oil-filled cable is self-compensating for water pressure and the heavy Tygothane jacket is much more resistant
to damage than a rubber jacketed cable.
However, Tygothane is susceptible to ultraviolet light damage and will harden and crack over time (typically two
years or less). The Tygothane oil-filled cables must be regularly inspected and changed out as they start to discolor,
craze or harden.
4-10 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Additionally, the Cage TMS can be equipped with equipment that is also housed in pressure-tolerant cans:
• Cameras
• Lights
• Various survey (third party) packages; ranging from responders to current meters.
Note that all Pressure-tolerant Cans have a design depth rating with a safety
margin.
Oceaneering-supplied equipment Pressure-tolerant Cans are designed for the
System’s maximum operating depth and have the appropriate safety margin built
into them. Exceeding the rated depth can destroy the Can and any equipment
CAUTION! contained in it.
Be aware that an implosion shockwave could also cause damage to other nearby
equipment.
Always check the depth ratings of any equipment that is being mounted to the
Cage TMS and do not exceed it.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-11
Millennium Plus System Overview
FO Section
OPAC Section
Vent/Vacuum Port
Figure 27: Telemetry Can Figure 28: Telemetry Can – Cover Removed
When the Telemetry Can is uncovered and extended, the Telemetry chassis is very vulnerable to damage, particularly
water damage. Extreme care must be taken to ensure that the TMS’ structure around the Telemetry Can is well
dried off to prevent seawater from dripping into the Telemetry Can chassis.
The Telemetry Can cover is very bulky and heavy; always use at least two
WARNING!! people and a lifting harness when removing or reinstalling the Telemetry
housing cover.
The Telemetry Can’s penetrator head contains the various electrical connectors that are required to connect the Top
Hat TMS’ external systems to the Telemetry Can’s internal components.
4-12 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
In addition, the vent/vacuum port has a sensor built into it that will indicate an alarm if the vent/vacuum port plug is
left off.
Note that the sensor is unable to differentiate between a missing plug and a plug that is in place but not fully
tightened.
Vent/Vacuum Port
Leaving the vent/vacuum plug off or loose is the single most common reason for
flooding the Telemetry Can.
CAUTION! ALWAYS double-check that the vent plug has been installed and retightened
before diving the vehicle after the Telemetry Can cover has been removed/
reinstalled.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-13
Millennium Plus System Overview
External Compass
Can
Compass
Module
Figure 30: Compass Can Figure 31: Compass Can – Cover Removed
Compass
Module
Figure 32: Telemetry Can – Cover Removed, Showing Internal Compass Module
4-14 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
• Hydraulic Power Unit (HPU); composed of a high-voltage three-phase electric motor driving a variable
displacement constant pressure hydraulic pump. The HPU provides the pressurized oil required for the
operation of the various subsystems. Note that the HPU used is identical to the Millennium Plus vehicle, in
order to decrease the required spares that must be carried the system.
• Hydraulic Oil Reservoir; composed of a five gallon (3.8 liter) reservoir that provides oil storage for the
hydraulic system.
• High Pressure Oil Filter; cleans the oil and prevents large particles from moving through the system,
damaging or blocking other components.
• CARDEV Water Removal Filter; removes small amounts of seawater that manage to contaminate the oil
• Pressure Monitoring Gauges; allows for the pressure monitoring of the various parts of the hydraulic system.
• In-Line Hydraulic Components; a group of active hydraulic components that perform specific functions
within the hydraulic system.
• Rate Control Unit (RCU); provides a number of rate (fixed flow, either on or off) hydraulic outputs.
• Thrusters; two horizontal provide the means to control the Cage TMS’ heading or lateral offset in the water.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-15
Millennium Plus System Overview
Figure 33: 110EHP (82KW) Hydraulic Power Unit Figure 34: 110EHP (82KW) Motor Data Plate
Note: The x’d out date shown on the motor data engraving above will have the date engraved on it when the motor
is manufactured.
4-16 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Grounding Lug
Grounding Lug
Grounding Lug
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-17
Millennium Plus System Overview
The reservoir has a nine-gallon capacity and a built-in level sensor that CTAG uses to provide the Pilot with a
graphic display of the current oil level.
4.4.3 Y-Strainer
4-18 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Body
Outlet
Inlet
Screen
Screen
Number 32 Cap
Systems are equipped with a low flow restriction, large particle (greater than .1inch / 2.5mm) strainer assembly that
mounts between the oil reservoir and the pump inlet. The strainer is intended to capture any large debris that may
damage the pump.
Note: Figure 38 depicts a Y-strainer mounted in a Cage Type TMS, but the same part is mounted in a similar manner
in both types of TMS systems.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-19
Millennium Plus System Overview
The Cardev water filter is a specialized hydraulic filter that will absorb small amounts of seawater that have
contaminated the hydraulic fluid.
Note: If the system’s hydraulic oil is contaminated with large amounts of water, the system must be completely
drained, flushed and refilled with clean hydraulic oil. The Cardev filter will not be able to clean the oil.
Cardev
Water Filter
3-Micron HP Oil
Filter Housing
A compensator is a flexible rubber bladder that holds a volume of oil. When the compensator is expanded by being
filled with oil, it will maintain a positive oil pressure in the comp circuit for as long as there is no oil lost from the
circuit.
Note: Water will only enter the comp circuit if the internal oil pressure becomes lower than the external pressure.
In the Cage TMS there are four independent compensators that maintain positive pressure within the Cage TMS’
oil-filled housings. The compensators and their functions are as follows:
• Valve Pack (VP) Compensator; supplies oil to the Proportional Control Unit (PCU) and Rate Control Unit
(RCU) Each valve pack is plumbed with a 10-psi check valve back to the reservoir, which will relieve any over-
pressure in the circuit.
4-20 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
• Tether/Umbilical Termination Can and Transformer Can (ELECT) Compensator; supplies oil to the Tether
Termination Can, the Umbilical Termination Can and the Transformer Can.
• Thruster Shaft Seals (SS) Compensator; which supplies oil to all of the thruster seals.
Tether/Umbilical Termination
Housing and Transformer
Housing
(ELECT) Compensator
Motor (MTR)
Compensator
Shaft Seal (SS)
Compensator
Each compensator is charged through an individual quick-disconnect fitting. A quarter-turn valve allows each
compensator to be isolated from its compensation circuit.
A vent fitting is provided for each compensator to release any trapped air. Each compensator has a water check/
drain port mounted directly to the bottom of each compensator.
The compensator pressure is normally kept at a positive pressure of between 5 and 7psi (.3~.5Bar) above ambient:
• Any leaks present will result in oil coming out, rather than water going in; a small external leak is infinitely less
damaging to the system than seawater ingress would be.
• It is usually a simpler process to find and repair an external leak than to repair damage caused by the ingress
of seawater into a compensated system.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-21
Millennium Plus System Overview
Prior to launching the system, check that each compensator reservoir’s quarter-
turn isolation valves are open and that the reservoir is filled to the proper pressure.
CAUTION!
Damage can occur if a compensator is left isolated from its respective circuit or if
the compensator circuit oil pressure becomes too low or is overfilled.
4-22 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
• Pressure Relief Valve; which is used to protect the system from high-pressure impulses, it is set to actuate at a
relief pressure 300psi (20.7 Bar) over the HPU high-pressure setting.
• Counterbalance valves; are installed in line with the rate valves on pan and tilt functions and are used to prevent
drifting of the functions.
Note: The Pressure Relief Valve takes a great deal of abuse while performing its function of protecting the system
hydraulics. The valve should be tested or changed out at regular intervals to ensure continued system
protection.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-23
Millennium Plus System Overview
The sub-assemblies are used in combination to manage the lay of the Tether on the Drum as well as the proper
Tether feed for both the Reel-in and Reel-out functions.
Aft Tether
Keeper
Forward Tether
Keeper
Drum Drive Assembly
Tether Sheave
Assembly
4-24 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Forward/Aft Tether
Drum Drive Keepers
Motor
Drum Drive
Assembly Tether Storage Drum
Assembly
Level Wind
Assembly
Sheave
Tether Sheave
Assembly
Tensioner
Assemblies
Tether Guide
When a Tether In command is input by the Pilot, the hydraulic motor mounted on the Drum Drive Assembly mounting
plate rotates both the Tether Storage Drum and the diamond screw for the Level Wind Spooling Assembly. As the
Tether Storage Drum rotates, the tether is spooled onto the drum.
At the same time, the hydraulic motor that drives the Tether Sheave provides a small amount of torque in the
opposite direction. This results in a small amount of back tension on the tether, so that it wraps snugly on the drum.
The Tether Sheave Assembly back tension and the Level Wind Assembly work together to prevent gaps, loose
wraps or overlaid wraps on the storage drum tether storage drum, which can cause difficulty in recovering tether,
damage to the Tether Drive Mechanism or tether.
It is important to constantly monitor the Tether as it is being spooled on to the Tether Storage Drum. Allowing loose
wraps, overlaid wraps or excessive gaps to form between the Tether wraps, can lead to jamming or slippage of the
Tether, as well as increasing the possibilities of damage to the Tether or the Tether Drive Mechanism.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-25
Millennium Plus System Overview
When a Tether Out command is input by the Pilot, the hydraulic motor mounted to the Tether Sheave Assembly
mounting plate rotates the Tether Sheave, which pulls tether off of the Storage Drum Assembly. The Level Wind
Spooling Assembly is synchronized to the Drum rotation and will follow the lay of the Tether.
At the same time, the hydraulic motor that drives the Storage Drum provides a small amount of torque in the same
direction as the Tether Sheave. This torque is insufficient to cause the Drum to turn unaided, but greatly reduces the
effort required by the Tether Shave to pull tether from the Drum. The drag of the Drum also results in small amount
of tension between Drum and Tether Sheave, which along with the pressure provided by the tensioner rollers,
maintains the necessary friction between the tether and Tether Sheave.
This friction is required for the Tether Sheave to effectively pull on the tether, as well as to prevent the drum from
over-running the Tether and causing it to become too slack, misfeeding, or binding up in the Tether Sheave.
In most cases, the counter system consists of an encapsulated reed switch mounted on the Tether Sheave mounting
plate. The sensor detects the passing of magnets attached to the circumference of the Tether Sheave.
Some systems have been refitted with the sensor and magnets mounted to the Tether Drum.
4-26 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The valves are dedicated to the operation and control of the tether drive mechanism, as well as control of the Cage
TMS’ thrusters.
Proportional Valve
Driver PCB
Proportional Valve
Assembly – 9ea
PCU Manifold
Figure 45: 16-Station Proportional Control Unit Figure 46: OII PWM PCB Version PCU
with Covers Removed
Two different versions of the PCU exist, the difference being the type of proportional amplifier used. The first uses a
single OII PWM proportional amplifier PCB, while the other version uses two Wandfluh U05 proportional amplifier
PCBs.
Both PCUs function in a similar manner. For detailed information on each version, see the maintenance section.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-27
Millennium Plus System Overview
The rate valves are used for the Hydraulic bypass, pan and tilt unit, Vehicle clamps and the Safety Latch on the
Cage TMS.
Pressure Adjustment
LP1 and LP2
Flow Control
RCU Valve Adjustments
Manifold
Figure 48: 11-Station Rate Control Unit, Cover Removed Figure 49: 11-Station Rate Control Unit
4.4.14 Thrusters
Provides the Pilot with the ability to manually rotate the Cage TMS heading. When combined with a heading sensor,
the thrusters will maintain a constant heading (Auto heading).
The Thrusters also provides the ability to adjust the Cage TMS’ lateral offset, which is useful when operating in high
water currents.
Starboard Thruster
Assembly
Thruster Shaft Seal
Compensator
Port Thruster
Assembly
4-28 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
4.4.15 Camera
The Cage TMS Camera (shown below, mounted to the Cage TMS Camera Pan & Tilt Unit) is used for several
operational functions:
• Used to observe the Vehicle when both exiting and entering the Cage TMS.
• Used to observe the spooling, unspooling of the tether from the Tether Drum.
• Used to observe operational conditions that can affect the tether; such as tether tending direction, slack or
excessive tension, coiling and binding of the tether as well possible physical damage, entrapment etc.
• The camera is also used the check the compensation and pressure gauges connected to the various Cage
TMS systems.
A second camera and light is located just below the Tether Drum and inboard of the Umbilical Termination (shown
in Figure 19). This camera is used to observe the operation of the Vehicle Clamps.
Camera
Pan and Tilt Unit
Figure 51: Cage TMS Camera and Pan/Tilt Unit Figure 52: Vehicle Clamp Camera and Light
4.4.16 Lighting
The Cage TMS features two independently controlled light circuits, each one capable of providing 500w of power.
Quantity and position of lights can be configured to suit the work task, but a typical arrangement would employ one
lamp on the pan and tilt unit to point in the same direction as the camera, A second lamp is mounted to illuminate
the Clamp Assemblies.
Lamp versions are becoming available that use high intensity LEDs instead of Quartz Halogen bulbs. The LEDs use
less power for a similar light level output and are more reliable and longer lasting than the Quartz Halogen bulbs.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-29
Millennium Plus System Overview
The light intensity levels can be adjusted from the potentiometers on the Pilot’s tray or from the Pilot Chair touch
screen.
Vehicle lamps are designed for use in water and should never be left on when the
CAUTION!
vehicle is not submerged.
It is critically important to ensure that the clamps are kept properly adjusted/
maintained and that the vehicle is carefully monitored for its security in the TMS
while launching/recovering. In addition, ensure that both the vehicle and TMS is
CAUTION!
kept trim and level by adjusting their lead ballast to compensate for equipment
or tooling changes. This is particularly true after a work package is added or
removed from either system.
The vehicle is held in the Cage TMS by the use of two clamp assemblies (shown highlighted in blue in Figure 53)
and a safety latch assembly (shown in Figure 54).
Each of the clamp assemblies are composed of two hydraulic cylinders, each cylinder can extend or retract a
clamping pad. Together, there are four hydraulically operated clamping pads that can be extended down from the
upper Cage TMS structure. The clamping pads contact the Vehicle’s foam block and will press the Vehicle down
against the lower frame, holding the Vehicle in place within the Cage TMS.
4-30 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The clamps, if properly adjusted and maintained, are capable of securely holding the vehicle in place during all
normal launch and recovery operations.
A Vehicle Safety Latch has been added to the lower starboard Cage framework to help prevent the Vehicle from
unintentionally exiting the Cage when conditions exceed the normal operating parameters of the system.
The spring-loaded Safety Latch will act as one-way stopper for the Vehicle. The Pilot must hydraulically retract the
Safety Latch before the Vehicle can exit the Cage. When the Vehicle is returned to Cage, the spring-loaded Safety
Latch will depress from the Vehicles weight and will then extend automatically to prevent the Vehicle from slipping
out of the Cage.
It will be necessary to manually release the Safety Latch each time the Pilot wishes to exit the Cage.
Note: The Vehicle Safety Latch is a standard feature of later Millennium Plus systems and will be retrofitted to earlier
systems.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 4-31
Millennium Plus System Overview
4-32 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Section 5:
Vehicle
Vehicle
Section Contents
5.0 Millennium Plus Vehicle ...............................................................................................................................5-1
5.1 Frame .......................................................................................................................................................5-4
5.1.1 Anodes and Fasteners....................................................................................................................5-4
5.2 Buoyancy / Ballast ...................................................................................................................................5-4
5.2.1 Foam Block.....................................................................................................................................5-5
5.2.2 Lead Ballast ....................................................................................................................................5-7
5.2.3 Lead Ballast Tray ............................................................................................................................5-7
5.3 Equipment and Termination Cans (Housings) .........................................................................................5-7
5.3.1 Oil- filled (Oil-Compensated) Cans (Housings) ..............................................................................5-8
5.3.2 Tether Termination Can (Oil-Filled) .................................................................................................5-8
5.3.3 Transformer Can.............................................................................................................................5-9
5.3.4 Electric Motor Housings (Hydraulic Power Packs – Gold Motor) .................................................5-10
5.3.5 Oil-Filled Cables ........................................................................................................................... 5-11
5.3.6 Pressure-Tolerant Cans (Housings) .............................................................................................5-12
5.3.7 Telemetry Can ..............................................................................................................................5-13
5.3.8 Water Alarms ................................................................................................................................5-14
5.3.9 Fiber Optic Can ............................................................................................................................5-15
5.3.10 Amplifier (Amp) Can ...................................................................................................................5-17
5.3.11 Transducer Can ..........................................................................................................................5-18
5.4 Hydraulic System ...................................................................................................................................5-19
5.4.1 Hydraulic Power Units (HPUs) .....................................................................................................5-20
5.4.2 Hydraulic Oil Reservoir .................................................................................................................5-22
5.4.3 Cardev Water Removal Filter .......................................................................................................5-22
5.4.4 High Pressure Filters ....................................................................................................................5-23
5.4.5 Y-Strainer ......................................................................................................................................5-24
5.5 Oil Compensation System .....................................................................................................................5-25
5.5.1 Hydraulic System Pressure Gauges.............................................................................................5-27
5.5.2 In-Line Hydraulic Components .....................................................................................................5-28
5.5.3 Proportional Control Unit (PCU) ...................................................................................................5-29
5.5.4 Rate Control Unit (RCU) ...............................................................................................................5-31
5.5.5 Propulsion.....................................................................................................................................5-32
5.6 Standard Equipment ..............................................................................................................................5-34
5.6.1 Cameras .......................................................................................................................................5-34
5.6.2 Depth Sensor................................................................................................................................5-34
5.6.3 Sonar System ...............................................................................................................................5-34
5.6.4 Optional Responder/Transponder ................................................................................................5-35
5.6.5 Lighting .........................................................................................................................................5-35
5.6.6 Manipulators .................................................................................................................................5-35
Millennium Plus System Overview
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-1
Millennium Plus System Overview
5-2 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Vertical Thruster
Assemblies – 4ea
Port Aft
Vectored Thruster Stbd Fwd
Vectored Thruster
Figure 57: Millennium Plus Vehicle Foam Block Removed – Stbd/Aft View
Stbd Fwd
Port Fwd Vertical Thruster
Vertical Thruster
Stbd Aft
Vertical Thruster
Telemetry Can Roller
Guide and Rails
Port Aft
Vertical Thruster
Port Fwd
Horizontal Thruster
Transformer Can
Telemetry Can
Port Rate
Control Unit (RCU)
Fwd Hydraulic
Power Unit (HPU)
Fiber Optic Can
Aft Hydraulic
Cardev Filter Power Unit (HPU)
Figure 58: Millennium Plus Vehicle Foam Block Removed – Port/Aft View
Note: The Amp Can is not present on all vehicles; see Sections 5.3.10 and 5.5.3 for additional details.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-3
Millennium Plus System Overview
5.1 Frame
The Millennium Plus Vehicle is constructed using a free-flooding frame to provide support and mounting areas for
all the components of the vehicle. The frame consists of structural members, brackets, mounting plates, skids, and
bumpers. Structural members and some mounting brackets are extruded 6061-T6 aluminum shapes welded to form
an open frame. The frame is lightly bead-blasted for a uniform matte finish.
Other brackets, which are also made of 6061-T6 aluminum, are anodized for corrosion protection and are bolted to
the frame with insulators.
Ultra High Molecular Weight (UHMW) polyethylene skids and bumpers are fastened to the sides and stern of the
main frame. This protects the vehicle from abrasion.
Aluminum plating is bolted to the underside of the frame to protect vehicle components from protruding objects and
to support the lead ballast.
5-4 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Figure 59: Millennium Plus Forward Foam Block Figure 60: Millennium Plus Aft Foam Block
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-5
Millennium Plus System Overview
The location of the data plate is underneath the port forward corner of the foam block as shown in Figure 62.
Note: Syntactic foam can lose buoyancy over time due to water absorption into the epoxy. The rate of water
absorption will vary with the depth, number of dives, amount/types of surface damage and the type/thickness
of any surface coatings, but can range to over a 10% loss of its buoyancy in a five-year period. This buoyancy
loss is permanent and drying out the syntactic foam will not recover the lost buoyancy. This is due to surface
cracking and the failure of microspheres near the surface of the foam block that will rapidly refill with water
when the foam block is re-submerged.
Note: All Millennium Plus Vehicles currently use microsphere Syntactic foam as their standard flotation. Be
aware that other types of floatation utilizing large (less than 1/4” (6.4mm) to greater than 10” (250mm)
diameter) thermoplastic, glass or ceramic spheres (known as macrospheres) are in wide use throughout
the industry. Their flotation and depth characteristics can vary widely while superficially appearing similar to
the Millennium Plus foam (Oceaneering-built ROV systems use microsphere floatation only).
Always use caution when adding floatation with unknown specifications, as that flotation could unexpectedly
fail if its depth rating is exceeded.
Syntactic foam is designed for a specific water depth rating and typically has
a relatively small safety margin (25% or less of its maximum depth rating is
common).
CAUTION!
Determining the depth rating (or density) of unmarked syntactic foam can be
difficult and exceeding the depth rating of the Syntactic foam can result in its
complete loss of buoyancy.
Microsphere foam is generally safe to drill into, but drilling into macrosphere
Syntactic foam can cause internal damage to the foam block macrospheres, up
CAUTION! to and including the total loss of the foam bock’s buoyancy.
Avoid drilling holes into any Syntactic foam unless you are sure of the type of
foam you have.
5-6 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Lead is a toxic material when its dust is breathed in or ingested. Lead is not
readily absorbed through the skin. But lead dust on the hands, skin, or clothing
can easily be transferred to the mouth by eating or drinking.
If you must cut or machine lead bricks, always wear a mask and ensure that
chips and particles are carefully cleaned up and properly disposed of.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-7
Millennium Plus System Overview
The Tether Termination Can contains lethal high voltage electrical connections.
WARNING!! Always ensure that proper Lock out / Tag Out (LOTO) procedures are followed
when working in the Tether Termination Can.
High Voltage
Termination Strips
Grounding Lug
Tether
Termination Can
Figure 63: Tether Termination Can, Oil-Filled Figure 64: Tether Termination Can,
Exploded View with Cover Removed
5-8 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The Starboard mid-ship stanchion provides support for the weight of the Syntactic Foam block. It is designed to be
temporarily removed to allow access to the Tether Termination Can.
Terminal Strips
Transformer Can
Transformer
Figure 65: Transformer Can, Oil-Filled Figure 66: Transformer Can, Cover Removed
The Vehicle Transformer Can is an oil-filled housing that contains a single high-voltage, step-down transformer with
multi-tapped primary and secondary windings.
The purpose of the transformer is to convert the high voltage from the tether to lower voltages required by the
Vehicle’s onboard electronics and lighting.
The transformer’s primary winding is connected to the Tether Termination Can through an oil-filled cable. The
transformers secondary windings are connected to the Telemetry Can by an oil-filled cable, where they supply
electrical power to the Vehicle’s various electrical power systems and lighting.
The Port mid-ship stanchion provides support for the weight of the Syntactic Foam block. It is designed to be
temporarily removed to allow access to the Transformer Can.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-9
Millennium Plus System Overview
Forward Hydraulic
Power Unit (HPU
The motor housing and the Pressure Balanced Oil-Filled (PBOF) connectors
connecting them to the tether termination contains lethal high voltage electrical
WARNING!! connections.
Always ensure that proper Lock out / Tag Out (LOTO) procedures are followed
when working on the motor housing or their PBOF connectors.
Both electrical motor stator windings are connected to the Tether Termination through oil-filled cables terminated
with Pressure Balanced Oil-Filled (PBOF) connectors.
In addition to providing protection against leaks and reducing weight, oil filling the motors also aids in cooling the
motor windings.
5-10 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
PBOF connectors allow oil from the cable to fill the slight void between the male and female parts of the connector
when they are mated. The oil is at a slightly higher pressure than ambient, which means that if a leak occurs, oil will
leak out, rather than seawater leaking in.
Conventional connectors form a dry one-atmosphere environment around the connector’s internal pins and
sockets. While it is important to ensure that all connectors are properly sealed when mated, it is especially true for
conventional connectors. Flooding this type of connector will often damage it to the point where it must be replaced.
Besides subsea connectors, oil-filled Tygothane cables are also connected to tubing penetrators, which are basically
hollow adaptors, allowing wires to pass directly from an oil-filled housing into the Tygothane tubing without using a
connector.
Tubing penetrators are used where a Tygothane cable connects to an oil-filled housing. The inside of the Tygothane
is therefore pressure-compensated by the oil from the housing to which it is connected.
Custom oil-filled Tygothane cables offer an advantage over traditional rubber molded cables in that they are easily
field-repairable and can be made with the exact number and types of electrical conductors required.
Traditional rubber jacketed cables have a dry core and under pressure the jacket will compress around the core.
If there is a thin spot, cut or an air bubble in the rubber jacket, the jacket can fail at that point. Seawater can then
wick up the cables core into the area around the connectors solder cups, shorting them out. An oil-filled cable is
self-compensating for water pressure and the heavy Tygothane jacket is much more resistant to damage than a
rubber jacketed cable.
However, Tygothane is susceptible to ultraviolet light damage and will harden and crack over time (typically two
years or less). The Tygothane oil-filled cables must be regularly inspected and changed out as they start to discolor,
craze or harden.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-11
Millennium Plus System Overview
The Vehicle features additional equipment that is also housed in pressure-tolerant Cans:
• Cameras
• Pressure Transducer (Paro)
• Lights
• Altimeter
• Sonar Head
• Survey Gyro
• Doppler Velocity Log (DVL)
• Various survey (third party) packages; ranging from Responders to Pipe Trackers
Note that ALL pressure-tolerant Cans have a design depth rating with a safety
margin.
Oceaneering supplied equipment pressure-tolerant Cans are designed for the
Vehicles maximum operating depth and have an appropriate safety margin built
in to them.
CAUTION! Exceeding the safety margin of any pressure-tolerant housing will destroy the
housing and any equipment contained in it.
Be aware that an implosion shockwave could also cause damage to the foam
block or other nearby equipment.
Always check the depth ratings of any equipment that is being mounted to the
Vehicle and do not exceed it.
5-12 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
End Cap
Housing
Vent/Vacuum Port
Roller-Carriage Assembly
Figure 68: Millennium Plus Telemetry Can, Vehicle Foam Block Removed
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-13
Millennium Plus System Overview
Figure 70 shows the Vehicle with the aft tunnel cover removed, the Telemetry Can extended from the aft tunnel and
with the Telemetry Can cover removed.
When the Telemetry Can is uncovered and extended, the Telemetry chassis is very vulnerable to damage, particularly
water damage. Extreme care must be taken to ensure that the foam block surfaces above the Telemetry Can are
first dried off to prevent seawater from dripping into the Telemetry Can chassis.
The Telemetry Can cover is very bulky and heavy; always use at least two
WARNING!! people and a lifting harness when removing or reinstalling the Telemetry
housing cover.
Vent/Vacuum Port
5-14 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
As part of your Pre-dive procedures, always double check to ensure that the vent/vacuum port plug is on tight.
The ‘missing plug’ sensor on the vent/vacuum port is not intended as a replacement
for Pre-dive checks or for physically checking and ensuring that the plug is in
place on the vent/vacuum port and is tight before each dive.
The sensor is intended only as a warning device in the event that the plug is left
CAUTION! off.
Take care not to over tighten the plug as that can damage the plug or vent/vacuum
fitting preventing a proper seal.
Always follow the Manufactures installation instructions when installing or reusing
fittings.
Leaving the vent/vacuum plug off or loose is the single most common reason for
flooding the Telemetry Can.
CAUTION! ALWAYS double-check that the vent plug has been installed and retightened
before diving the vehicle after the Telemetry Can cover has been removed/
reinstalled.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-15
Millennium Plus System Overview
Use care when reinstalling connectors on the penetrator head. Carefully inspect
CAUTION! each bulkhead connector receptacle (BCR) to ensure that the internal o-ring is in
place (if applicable).
The FO Can chassis is bulky. Always use care when handling the Fiber Optic Can
CAUTION!
housing.
5-16 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Wandfluh Current
Amp PCBs
Figure 72: Amp Can Figure 73: Amp Can with Cover Removed
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-17
Millennium Plus System Overview
Pressure Transducer
Can
Pressure Transducers
Connector
Figure 74: Transducer Can Figure 75: Transducer Can with Cover Removed
5-18 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
• Hydraulic Power Unit (HPU); composed of a high-voltage three-phase electric motor driving a variable
displacement constant pressure hydraulic pump. The HPU provides the pressurized oil required for the operation
of the various subsystems. Note that the Millennium Plus vehicle utilizes two identical HPUs.
• Hydraulic Oil Reservoir; composed of a single 9-gallon (34 Liter) reservoir that provides oil storage for the
hydraulic system.
• High Pressure Oil Filters; cleans the oil and prevents large particles from moving through the system, damaging
or blocking other components. Note that each HPU has its own dedicated HP filter.
• CARDEV Water Removal Filter; removes small amounts of seawater that manage to contaminate the oil.
• Pressure Monitoring Gauges; allows for the pressure monitoring of the various parts of the hydraulic system.
• In-Line Hydraulic Components; a group of active hydraulic components that perform specific functions within
the hydraulic system.
• Pressure Relief Valve; controls over-pressure spikes in the hydraulic system.
• Counterbalance valves; prevents drifting or sagging of the pan/tilt or manipulators.
• Check Valves; allows the two hydraulic pump outputs to be combined.
• Proportional Control Unit (PCU); provides a number of proportional (variable) hydraulic outputs.
• Rate Control Unit (RCU); provides a number of rate (fixed flow, either on or off) hydraulic outputs.
• Thrusters; four vertical, four horizontal provide the means to control the Vehicle’s movement in the water.
Pinhole leaks can cause both high-pressure injection injuries and atmospheric
fogging.
High-pressure injection is where hydraulic oil under high pressure is injected into
WARNING!!
or cuts a part of the body; most commonly the hand.
Never use your hands to feel for hydraulic leaks when the hydraulic system is
operating.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-19
Millennium Plus System Overview
PBOF Connector
Aft HPU
Forward HPU
Figure 76: Forward and Aft HPUs Figure 77: 110EHP (82KW) Motor and 71cc Pump
Note: The plate shown in Figure 78 is only an example. For each actual plate, the “Date XX/XX/XX - 00X” field will
depict the HPU’s actual date of manufacture.
5-20 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Grounding Lug
Grounding Lug
Grounding Lug
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-21
Millennium Plus System Overview
5-22 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Note: There are two alternate mounting oppositions for the High Pressure Oil Filter; horizontal mounting as shown
on the upper left photo and vertical mounting as shown on the upper right photo. The port side filter is
mounted only in a vertical orientation, as shown in the lower center photo.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-23
Millennium Plus System Overview
5.4.5 Y-Strainer
Main Reservoir
Body
Outlet Inlet
Screen
Screen
2-228 Buna N70 O-ring
2-228 Buna N70 O-ring
Number 32 Cap
Number 32 Cap
Systems are equipped with a low flow restriction, large particle (greater than 0.1inch / 2.5mm) strainer assembly
that mounts between the oil reservoir and the pump inlet. The strainer is intended to capture any large debris that
may damage the pump.
5-24 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Fwd Motor
Compensator PCU and RCU
Compensator
Aft Motor
Compensator
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-25
Millennium Plus System Overview
In Millennium Plus Vehicles, there are five independent compensators that maintain positive pressure within the
Vehicle’s oil-compensated housings.
The compensators and their functions are as follows:
• Valve Pack Compensator (PCU); supplies oil to the Port and Starboard Proportional Control Units (PCUs)
and the Port and Starboard Rate Control Units (RCUs). Each valve pack is plumbed with a 10-psi check
valve to tank in case of valve leakage or thermal expansion of the comp oil.
• Termination Can/Transformer Can (TERM) Compensator; supplies oil to the Tether Termination Can and
the Vehicle Transformer Can.
• Port Motor (AFT) Compensator; Supplies oil to the port motor. 20psi (1.4Bar) check valves prevent
communication between the two housings in case of a failure of one of the two motors.
• Starboard Motor (FWD) Compensator; Supplies oil to the starboard motor. 20psi (1.4Bar) check valves
prevent communication between the two housings in case of a failure of one of the two motors.
• Thruster Shaft Seals (SS) Compensator; supplies oil to each of the individual thruster seal housings.
Each compensator is connected to an individual pressure gauge that allows for consistent filling when performing
maintenance checks or repairs. The pressure gauges also allow for the monitoring of any pressure changes due
to oil loss, valve leakage, thermal expansion, air bubbles etc. in operation by using the Vehicle Camera to view the
gauges.
The compensator pressure is normally kept at a positive pressure of between 5 and 7psi (.3~.5Bar) above ambient:
• Any leaks present will result in oil coming out, rather than water going in; a small external leak is infinitely
less damaging to the system than seawater ingress would be.
• It is usually a simpler process to find and repair an external leak than to repair damage caused by the
ingress of seawater into a compensated system.
Note: The names shown in parentheses indicate the label name that is attached to the pressure gauges.
Note: On some systems, the Termination Can/Transformer Can (ELECT) Compensator has an oil level sensor
attached to it, allowing CTAG to display the oil level on the graphics display screen.
Each compensator is normally charged through an individual quick-disconnect fitting, the location of which can
vary between Vehicles, but is generally mounted to the top plate of the individual compensator. A quarter-turn valve
installed in each compensator circuit’s feed line allows the compensator to be isolated from its compensation circuit.
A vent fitting is provided on each compensator to assist in removing any air that may become trapped in the
compensator. Because water gravitates to the lowest point of the housing, each compensator has a water check/
drain port mounted directly on its bottom.
5-26 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Prior to launching the system, check that each compensator reservoir’s quarter-
turn isolation valves are open and that the reservoir is filled to the proper pressure.
CAUTION!
Damage can occur if a compensator is left isolated from its respective circuit or if
the compensator circuit oil pressure becomes too low or is overfilled.
Note: Compensators are typically filled to a range between 5 and 7 PSI (.3~.5 Bar). Be aware that if you are working
at shallow depths in unusually warm water. You will likely need to decrease the on deck comp pressures prior
to your dive, in order to maintain your set comp pressure while working. This is due to the heat expansion of
the comp oil in water. Consequently, if you are operating in extreme depths the comp pressures may need be
to be slightly increased in order to compensate for the loss of comp oil volume as the oil shrinks due to
pressure and cold at depth.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-27
Millennium Plus System Overview
Note: The Pressure Relief Valves take a great deal of abuse while performing their function of protecting the system
hydraulics. The valves should be tested or changed out at regular intervals to ensure continued system
protection.
5-28 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Both the Starboard and Port PCUs are configured in a similar manner, three of it’s four proportional direction valves
are dedicated to thruster control, while the fourth proportional direction valve along with the single proportional
reducing/relieving valve is dedicated to tooling control.
Command for each thruster control valves is provided by movement of the joystick, with the command for the tooling
valve provided by input to CTAG.
The valves are controlled by proportional amplifier cards, which take low-power commands from the Telemetry Can
and provide high-power drive signals for the coils on the valves. Two versions of card have been used in Millennium
Plus systems; Wandfluh U05 and OII PWM.
In most systems, the amplifier card is housed inside the PCU along with the valves. However, some systems have
been built with the amplifier cards housed in the pressure-tolerant Amplifier Can. As such, the PCU can have one
of three internal configurations:
• Option A - w/ terminal strips only, which is used only with an external Amp Can, containing the Wandfluh U05
motherboard proportional amplifier PCBs.
• Option B - w/ Wandfluh U05 proportional amplifier PCBs.
• Option C - w/ OII built Pulse Width Modulated (PWM) PCB.
The internal PCBs take the place of the external Amp Can. See the maintenance section for addition details.
Note: The PCU containing the internally mounted OII PWM PCB is by far the most common version of PCU in use
on Millennium Plus Vehicles. Each of the PCU versions is functionally equivalent to the other versions and
operates in a similar manner.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-29
Millennium Plus System Overview
Proportional Pressure
Directional Valve
Proportional Pressure
Reducing/Relieving Valve
5-30 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Pressure Adjustments
and Flow Controls
Pressure Adjustment
LP1 and LP2
Flow Control
RCU Valve Adjustments
Manifold
Figure 91: 11-Station Rate Control Unit, Cover Removed Figure 92: 11-Station Rate Control Unit
Note: The Pressure Reducing Valves (PRV) are marked externally on the RCU as PRV1 (LP1) and PRV2 (LP2) and
are often referred to as low-pressure adjustments. The pressure setting of each is indicated by the (P/S)LP1
and (P/S)LP2 gauges on the Vehicle. Be aware that while the PRVs set the output pressures to a value that
is less than the RCU input (system) pressure, the pressure setting can still be quite high. Always monitor the
value displayed by the gauge as they are being set, to avoid over-pressuring any equipment connected to
the RCU.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-31
Millennium Plus System Overview
5.5.5 Propulsion
Thrusters are composed of axial piston hydraulic motors driving three-bladed aluminum propellers housed in Kort
nozzles.
Millennium Plus Vehicles are equipped with eight hydraulic thrusters, four thrusters for vertical movement and four
thrusters set up in the horizontal plane in a 45-degree vectored configuration.
The four vertical thrusters are grouped as two sets of two thrusters, one set composed of the forward port/starboard
thrusters and the second set composed of the aft port/starboard thrusters. Splitting the thrusters into forward and
aft sets allows the Vehicle pitch to be easily trimmed as required.
The four horizontal thrusters are configured in a vectored thrust pattern. Vectored thrust means that the Vehicle
combines the direction and force of all four horizontal thrusters in order to produce a resultant thrust in any direction
in the horizontal plane. Combining the thrust/vector of four independent thrusters will result in increased power and
maneuverability. Axial Vehicles combine only two thrust vectors (fwd/rev & lateral).
The vectored configuration is considered to be superior over an axial configuration for three primary reasons:
• First, ALL four horizontal thrusters contribute thrust to the Vehicle’s movement in horizontal ANY direction. For
example; in moving forward in an axial arrangement, only the port and starboard thrusters are used, in the
vectored arrangement, all four thrusters will contribute to the Vehicle’s forward thrust.
• Secondly, because the thrusters are mounted in a way that keeps the water paths clearer of obstructions,
it makes the thrust delivered in each direction more consistent and more powerful than an axial thruster
arrangement would be.
• Thirdly, the Vehicle’s center of rotation is in the middle of the Vehicle, which makes Vehicle turning movements
smoother and more responsive than an axial thruster arrangement.
As the vectored Vehicle in Figure 93 shows, when commanded to move forward, water moves equally through all
four thrusters. Each thruster contributes approximately equal thrust towards the Vehicle’s forward movement.
As the axial Vehicle in Figure 94 shows, with the same forward command, water moves only through the port and
starboard thrusters, the lateral thruster does not contribute to the forward movement at all. Additionally, the water
flow through each thruster is partly obstructed by the Vehicle’s internal components, which reduces the efficiency
of the two thrusters.
Regardless of the horizontal direction of movement, a vectored thruster configuration will always produce stronger
thrust than a similar sized axial thruster arrangement.
5-32 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Vehicle Center
of Rotation
Vehicle Center
of Rotation
Figure 93: Vectored Thrust – Water Flow Figure 94: Axial Thrust – Water Flow
Propeller
Forward Port
Vertical Thruster
Kurt Nozzle Forward Stbd
Vertical Thruster
Pedestal
Assembly
Motor
Aft Port
Vertical Thruster
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-33
Millennium Plus System Overview
5.6.1 Cameras
The Vehicle can be equipped with any of several different camera systems. Standard camera packages can vary
due to changing manufacturers or manufacturers improving their technology.
Camera power on/off and zoom/focus controls (if equipped) can be controlled from the Pilot Tray, CTAG soft switches
or from the Pilot Chair touch screen.
Typically the cameras found on a Millennium Plus are:
• Color camera; equipped with remote zoom and focus functions, mounted on a forward hydraulically
operated pan and tilt unit.
• Low light monochrome mini CCD wide-angle, fixed focus camera, often mounted alongside the color
camera on the same pan and tilt unit.
• Monochrome mini CCD wide angle, fixed focus camera, hard mounted on the aft of the Vehicle. Used with
the Cage type TMS to assist the pilot in entering the Cage and viewing the tether. On systems with Top hat
TMS; the camera is mounted on top of the foam block for viewing the tether.
• Color CCD with integrated pan/tilt (Dome Camera) equipped with remote zoom and focus functions (not
normally found on a Millennium Plus, but can be fitted when needed).
• Additional specialized cameras such as HD (High Definition), SIT (Silicon Intensified Target) or stills camera
can be mounted to the Vehicle or to tooling packages as required.
5-34 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
5.6.5 Lighting
The Millennium plus Vehicle features four independently controlled light circuits, each one capable of providing up
to 500w of power. Quantity and position of lights can be configured to suit the work task, but a typical arrangement
would employ one lamp on the pan and tilt unit to point in the same direction as the camera, two lamps mounted on
the Vehicle frame looking forward and one lamp mounted looking aft to provide light for the aft camera.
The lamps typically used are 250w Quartz Halogen. Lamp versions are becoming available that use high intensity
LEDs instead of Quartz Halogen bulbs. The LEDs use less power for a similar light level output and are more
reliable and longer lasting than the Quartz Halogen bulbs.
The light intensity levels can be adjusted from the potentiometers on the Pilot’s tray or from the Pilot Chair touch
screen.
The vehicle can also be fitted with optional High Intensity Discharge (HID) lamps. The fixed-intensity (i.e. non-
dimmable) HID lights produce a higher intensity of light and consume slightly less power than standard Quartz
Halogen lamp, but are slightly larger. When turned on, HID lamps take several minutes to reach full brightness.
When turned off, they must complete a cool-down cycle of several minutes before they can be turned back on.
Vehicle lamps are designed for use in water and should never be left on when the
CAUTION!
vehicle is not submerged.
5.6.6 Manipulators
The Millennium Plus Vehicle is typically equipped with two rate manipulators, which can be any one of several
commercially available or Oceaneering-constructed types. For certain tasks the rate manipulators can be replaced
with spatially correspondent manipulators.
Manipulators are mounted on the forward lower frame of the vehicle on opposing sides. The two manipulators are
not identical in reach and working envelope, but they mirror each other with respect to certain functions. Particularly
the swing and wrist yaw functions, which work from an outboard position towards the center of the vehicle.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 5-35
Millennium Plus System Overview
The manipulators are pedestal-mounted on heavy aluminum plates welded to the lower vehicle frame. Flexible
tubing to the manipulator functions has a braided stainless steel jacket to protect it from chafing and locked in
pressure from the pilot operated (PO) check valves. The tubing is also protected by aluminum covers, where
possible, to prevent snagging during intervention activities. The manipulator jaws are designed to firmly grip tools
equipped with 3/4” (1.9cm) T-handles.
All functions of rate-controlled manipulators are controlled by solenoid operated rate valves located in the two
11-station rate control units (RCU). This is the most reliable and easily maintained type of manipulator control
system.
A seven-function hand controller operates both the starboard and port manipulators with the operator switching
between the two with a CTAG soft switch located on the upper bar of the CTAG control panel.
All functions of spatially correspondent manipulators are controlled by manufacturer supplied servo/proportional
valves, which are in turn controlled by a custom hand controller dedicated to the particular manipulator in use.
5-36 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Section 6:
Electrical Power Distribution
Electrical Power Distribution
Section Contents
6.0 Electrical Power Distribution.......................................................................................................................6-1
6.1 Overall Description of Electrical Power Distribution Components ...........................................................6-3
6.2 Millennium Plus Console ..........................................................................................................................6-7
6.3 Power Distribution Unit (PDU) .................................................................................................................6-9
6.4 PDU Component Layout ........................................................................................................................6-12
6.5 GFI Ground Fault Monitoring/Interrupting ..............................................................................................6-13
6.6 System Transformers .............................................................................................................................6-14
6.6.1 House Power Transformer............................................................................................................6-14
6.6.2 Vehicle and TMS Electrical Transformer (VEH ELEX & CAGE ELEX).........................................6-15
6.6.3 HPU Boost Transformers..............................................................................................................6-15
6.7 HPU Boost Transformer Housing and Termination J-Box ......................................................................6-16
6.8 Winch Stationary J-Box ..........................................................................................................................6-18
6.8.1 Winch Stationary Termination J-Box GFI......................................................................................6-19
6.9 Winch Sliprings ......................................................................................................................................6-20
6.10 Winch Rotating J-Box ..........................................................................................................................6-22
6.11 Armored Lift Umbilical ..........................................................................................................................6-22
6.12 TMS Umbilical Termination Can ...........................................................................................................6-24
6.13 TMS Transformer Can..........................................................................................................................6-25
6.14 TMS HPU .............................................................................................................................................6-26
6.15 TMS Sliprings .......................................................................................................................................6-26
6.16 TMS Tether Termination Can (Rotating J-Box) ....................................................................................6-27
6.17 Tether ...................................................................................................................................................6-28
6.18 Vehicle Tether Termination Can ...........................................................................................................6-28
6.19 Vehicle Transformer Can .....................................................................................................................6-29
6.20 Aft/Forward HPUs ................................................................................................................................6-30
Millennium Plus System Overview
The Millennium Plus System utilizes High Voltage, High Current components
that can pose Lethal Hazards to personnel who operate and maintain these
components.
WARNING!! High Voltage AC is present in all power transformers, distribution boxes and
panels during normal operation.
Accidental contact with high voltage can result in severe burns and/or heart
failure.
Always use Lock Out / Tag Out (LOTO) procedures and a ‘Two Person’ work
WARNING!!
rule when performing maintenance on High Voltage components.
Always refer to the drawings supplied with your system before undertaking any
WARNING!!
checks or repairs to any part of your system.
The source of the 480VAC (nominal) input power will depend on the operating environment in which the system has
been installed; in a typical arrangement, the source will be ‘dirty’ or ‘raw’ power supplied by the installation or vessel.
This power is generally used directly for powering the HPU motors and a small (15KVA) motor generator (Mini-MG).
The Mini-MG provides ‘clean’ power for the Console, TMS and Vehicle electrical/electronic systems.
The terms ‘dirty or raw’ power refers to the fact that electrical power supplied by the installation (Rig or Vessel) tends
to be less than ideal, suffering from voltage sags, surges, frequency shifts and high frequency impulse noise, all of
which can affect electronic systems to a greater or lesser degree.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-1
Millennium Plus System Overview
The HPU motors are relatively immune to the effects of dirty power, although extended voltage sags can cause an
over-current condition in the motors, which in turn can lead to over-heating and nuisance tripping.
Using a Mini-MG set provides both electrical isolation from the power source and provides the stable, ‘clean’ power
that the Millennium Plus’ more delicate systems require for reliable operation.
Other power schemes are possible, such as high power motor generators, diesel generators or high power UPS
(250KVA+) systems. In such cases there would be a shared common input to each of the PDU breakers rather than
a split ‘Dirty/Clean’ power arrangement.
As the source power arrangements can and do change from system to system, they are outside the scope of
this manual. Consult the supplied manufactures data or manuals provided for information on the power source/s
supplied with your system.
You can also contact the Oceaneering Installations group or your local Technical Department for additional
information or assistance with power problems.
Note: While the term “Cage” has often been used to refer to any type of TMS (Tether Management System), it can
cause confusion to call every TMS a Cage. However, as most electrical schematics, Pilot Console and PDU
labels use the term “Cage”, this misuse cannot be avoided. In this document, TMS is used where possible
when referring to the Cage, except when referencing the electrical schematic, Pilot Console or PDU labels.
Note: In many commonly used documents such as technical manuals, manufacturer’s data sheets or drawings,
you will often notice that inconsistent nominal mains AC Voltages are specified. In practice, is not unusual to
see 110VAC given in one document and 127VAC given in another, with both documents referring to the same
input. The reason for this inconsistent variation is simply the fact that there is no one mains AC Voltage
standard, depending on where you are located (or even the time of day) in the power distribution grid, the
actual measured mains voltage can vary widely. Variations between 85VAC to 135VAC in the Americas and
200VAC to 260VAC in Europe, Africa/Middle East or Australia/Asia are not at all unusual.
Consequently, the mains voltage specified in a document is often an arbitrary value (in the nominal range)
that the person writing the document decides to use. It is important for technicians to realize, that when a
mains AC voltage is specified, your actual AC voltage will probably be different than what is specified, but it
should be within the nominal range of the equipment being powered.
6-2 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-3
Millennium Plus System Overview
• TMS Umbilical Termination; an oil-filled and compensated termination box on the TMS where the electro-
optical core of the Armored Lift Umbilical is terminated, allowing the electrical conductors and FO fibers to
be separated from the Lift Umbilical and routed to either the TMS or Vehicle. Connections intended for the
Vehicle are routed directly to the TMS sliprings. Electrical connections intended for the TMS are routed to
the TMS Transformer Can and the TMS HPU. FO connections are routed to the TMS Telemetry Can.
• TMS Transformer Can; an oil-filled and compensated can containing the step-down transformer that
reduces the TMS high-voltage electrical power (1300VAC-CAGE ELEX) to a more usable range of 120VAC
and 17VAC.
• TMS Sliprings; allows electrical power and Fiber Optic signals to be coupled into the Tether. The TMS
Slipring assembly is similar to the Winch Slipring assembly, with the exception that it has fewer electrical/
FO passes and is oil-filled and compensated.
• TMS Tether Termination (Rotating J-Box); an oil-filled and compensated termination box that serves as
the termination point from the TMS slipring to the Tether.
• Tether; the flying tether is a flexible, lightweight cable that provides electrical and FO links to and from the
vehicle.
• Vehicle Tether Termination Can; an oil-filled and compensated termination box on the Vehicle where the
Tether is terminated, allowing the electrical and Fiber Optics to be routed to the Vehicle Telemetry Can, FO
Can, Transformer Can and Port/Starboard HPUs.
• Vehicle Transformer Can; contains the oil-filled and compensated can that contains the step-down
transformer that reduces the Vehicle high-voltage electrical power (1300VAC-VEH ELEX) to a more usable
range of 120/17VAC.
6-4 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
480VAC
480VAC
PILOT CONSOLE
480VAC
OPAC
MEGACON
ADAPTOR
DECK CABLES
Note: The block diagram shows both the Megacon and DTEC ground fault detection units. Systems will have one
or the other installed, not both.
Note: Contactor interlocking and GFI shut down is handled differently depending on which GFI System is used. See
your system drawing and Surface Power Detail document for additional details on contactor interlocking.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-5
Millennium Plus System Overview
BOOST XFMR
TERM J-BOX
WINCH STATIONARY
TERMINATION J-BOX
DETEC
SENSE RESISTER
MEGACON
ADAPTOR
MEGACON
ADAPTOR
MEGACON
ADAPTOR
WINCH SLIPRINGS
LIFT UMBILICAL
TELEMTRY CAN
TETHER
AFT HPU
3Ø 3000VAC
TELEMTRY CAN
6-6 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The two GFI systems, Megacon and DTEC, operate and display ground faults in a somewhat different manner, but
both systems perform the same electrical protection functions and will shut down each monitored sub-system in a
similar manner.
The GFI system monitors for ground faults in each of the following systems:
• 480VAC INPUT; 3Ø 480VAC system supply (not monitored on all systems)
• CAGE ELEX; 1Ø 1300VAC power to the TMS (Cage) step-down transformer
• VEH ELEX; 1Ø 1300VAC power to the Vehicle step-down transformer
• CAGE HPU; 3Ø 3000VAC power to the TMS (Cage) Hydraulic Power Unit (HPU)
• AFT HPU; 3Ø 3000VAC power to the Vehicle Aft Hydraulic Power Unit (HPU)
• FWD HPU; 3Ø 3000VAC power to the Vehicle Forward Hydraulic Power Unit (HPU)
Note: The 1Ø 1300VAC and 3Ø 3000VAC values given above are the typical voltages found at the TMS or Vehicle
transformer/HPUs. The actual value at the surface TMS/Vehicle transformer will be higher due to the voltage
drops incurred in the Umbilical.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-7
Millennium Plus System Overview
See the individual Console Overview manuals for additional detail on each console version.
In each console version, the power control switches are located on the Pilot Console’s Power Tray and each switch
operates in the same manner, refer to Figure 98 and Figure 99 for power switches and GFI layout.
• CONSOLE POWER ON/OFF; controls the CONSOLE contactor in the PDU, which supplies “switched
120VAC “ power to the Console power supplies and to the CAGE and VEH ELEX power switches.
• CAGE ELEX; controls the CAGE ELEX contactor in the PDU. This contactor supplies single-phase
480VAC electrical power to the TMS (Cage) electrics step-up transformer, which in turn provides single
phase 1300VAC to the TMS (Cage) electrics. CONSOLE POWER must be enabled before the CAGE ELEX
power switch can be enabled.
• VEH ELEX; controls the VEH ELEX contactor in the PDU. This contactor supplies single-phase 480VAC
electrical power to the Vehicle electrics step-up transformer, which in turn provides single phase 1300VAC
to the Vehicle electrics. CONSOLE POWER must be enabled before the VEH ELEX power switch can be
enabled.
• CAGE HPU; controls the CAGE HPU contactor in the PDU. This contactor supplies 3Ø 480VAC electrical
power to the TMS (Cage) Boost (step-up) Transformer, which in turn provides 3Ø 3000VAC to the TMS
(Cage) HPU. The CAGE ELEX power switch must be enabled before the CAGE HPU power switch can be
enabled.
• AFT/PORT HPU; controls the Aft HPU contactor in the PDU. This contactor supplies 3Ø 480VAC electrical
power to the Vehicle Aft HPU Boost (step-up) Transformer, which in turn provides 3Ø 3000VAC to the
Vehicle Aft HPU. The VEH ELEX power switch must be enabled before the AFT/PORT HPU power switch
can be enabled.
• FWD/STBD HPU; controls the Forward HPU contactor in the PDU. This contactor supplies 3Ø 480VAC
electrical power to the Vehicle Forward HPU Boost (step-up) Transformer, which in turn provides 3Ø
3000VAC to the Vehicle Forward HPU. The VEH ELEX power switch must be enabled before the FWD/
STBD HPU power switch can be enabled.
6-8 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Note: On a number of older Millennium Plus systems, the Power Tray HPU on/off buttons are marked as PORT and
STBD, instead of the current labeling of AFT/PORT and FWD/STBD. Millennium HPUs are arranged in a
forward/aft arrangement. Be aware that on the old style Power Trays, the PORT control will operate the Aft
HPU and the STBD control will operate the Forward HPU.
Always refer to the drawings supplied with your system before undertaking any
WARNING!!
checks or repairs to any part of your system.
A number of different PDU designs have been implemented to meet the varying environments in which Millennium
Plus systems have been installed, many of these PDUs have common elements and generally similar functions with
only the physical layout of the components differing.
The PDU is the heart of the Millennium Plus power distribution. The PDU, in conjunction with the Pilot Console
power switches provides for all of the system electrical power switching. The PDU is the location of the circuit
breakers, contactors/overload relays, voltage, current and phase monitoring functions for the 480VAC input power.
Millennium Plus systems use one of two different High Voltage Ground Fault Interrupting/Monitoring (GFI/M)
systems, namely the DTEC or Megacon. The DTEC GFI uses sense resistors to connect to the monitored circuit,
while the Megacon GFM uses Voltage Adaptor Modules for voltages above 500VAC and a direct connection for
voltages that are less than 500 volts.
In Megacon GFM equipped systems, the voltage adaptor modules for the Vehicle and TMS electrical supply step-up
transformers are located in the PDU. For the CAGE, AFT and FWD HPU boost transformers, the voltage adaptor
modules are located in the Winch Stationary Termination J-Box.
In DTEC GFI equipped systems, the sense resistors for the 480VAC source are located in the PDU. For the
Vehicle and TMS electrical supply step-up transformers the sense resistors are directly connected to the step-up
transformers. For the CAGE, AFT and FWD HPU boost transformers, they are located in the Winch Stationary
Termination J-Box.
Note: The names Ground Fault Monitoring (GFM) and Ground Fault Interrupting (GFI) are terms that have been
used interchangeably to mean the same thing. To some extent the terms are region specific; GFM will be
encountered more often in Europe/AME, while GFI is more common in the Americas, just be aware that the
two terms refer to the same process.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-9
Millennium Plus System Overview
Note: The DTEC GFI system is being phased out in favor of the Megacon GFI system. The DTEC GFI is no longer
being installed in new built Millennium Plus systems.
Note: Some versions of the PDU will also contain the Vehicle and TMS step-up transformers and/or house
transformers. In other systems, they are located in a separate enclosure or cabinet. Consult your supplied
documentation.
The Power Distribution Unit (PDU) contains the power on/off Breakers and
contactors for the TMS and Vehicle electrical systems and their HPU Power
WARNING!! Packs. When working on any of these systems, the PDU power source
must be Locked Out/Tagged Out to protect personnel against the accidental
activation of these controls.
6-10 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Electrical Power
Electrical Power Breaker BK-6
Breaker BK-1
Input Voltage
Meter
Input Voltage
Frequency Meter
Figures 100 and 101 illustrate the typical PDU enclosures found in Millennium Plus systems, highlighting a few of
their differences.
In a few of the very early Millennium Plus systems, the PDU panel is located in a wooden cabinet, however the PDU
component panel layout is still similar to the PDU illustrated in Figure 102 on the next page.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-11
Millennium Plus System Overview
Circuit Breakers
Note: Figure 102 shows the DTEC GFI sense resistors mounted in the PDU. Depending on which GFI system is
actually in use, will determine whether sense resistors or Megacon Voltage Interface modules are used in
the PDU.
See the Millennium Plus Surface Power Detail section for additional detail and functional description of the Millennium
Plus PDU.
6-12 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
A Ground Fault simply defined, is a fault or condition that establishes an electrical connection between a previously
isolated electrical circuit and the chassis ground. As the Millennium Plus system uses 3Ø 3000VAC electrical
power for its HPU motors and 1Ø 1300VAC for Vehicle and TMS electronic systems, a ground fault can present a
potentially lethal situation for anyone working on the system.
The Ground Fault (GF) system will constantly monitor the vehicle’s high voltage circuits for the presence of a ground
fault.
If a fault develops, the GF system will shut down the faulty circuit by de-energizing the contactor and giving the
operator a warning that there has been a fault detected on the circuit.
There are two different GF systems used in Millennium Plus Systems; Megacon GFM system and the DTEC GFI.
The Megacon GFI is replacing the older DTEC GFI in all new built systems, but the DTEC GFI can still be found in
use on many systems.
The DTEC GFI PCB requires external sense resistors for all of its monitored circuits while the Megacon GFI requires
an external voltage adapter only if the voltage to be monitored is higher than 500VAC.
Megacon Voltage Adapter Modules for the Cage ELEX and Vehicle ELEX Step-up Transformers are located in
the PDU, while the Voltage Adapter Modules for the HPU Boost Transformer are located in the Boost Transformer
Termination J-Box.
The DTEC Systems sense resisters are located in the PDU for the 3Ø 480VAC supply input voltage, mounted
directly to the secondary terminals of the Cage ELEX and Vehicle ELEX step-up transformers and located in the
Boost Transformer Termination J-Box for the HPU Boost Transformers.
Note: All Vessels and Rigs monitor their 3Ø 480VAC systems for ground faults. On systems using “raw” rig or vessel
3Ø 480VAC power (i.e. those without a mini-MG or isolation transformer) , it will be necessary to disconnect
the DTEC sense resistors from the 3Ø 480VAC supply input, in order to prevent interference to rig/vessel GFI
system.
Note: See Millennium Plus Surface Power Distribution section for additional details and functional descriptions of
the GFI/M shut down and contactor interlocking.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-13
Millennium Plus System Overview
The Millennium Plus system utilizes four different types of transformer, each of which serves a different purpose:
• House Power transformer.
• Vehicle/TMS Electrics step-up transformers (2 off)
• Vehicle/TMS HPU step-up transformers (3 off)
• Vehicle/TMS step-down transformer (2 off)
6-14 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
6.6.2 Vehicle and TMS Electrical Transformer (VEH ELEX & CAGE ELEX)
The Vehicle Electrical (VEH ELEX) and TMS Electrical (CAGE ELEX) Step-up transformers are identical single-
phase transformers with a 1Ø 480VAC primary winding and with a multi-tap 1200/1250/1300/1350/1400VAC
secondary.
The transformers are rated at 6KVA and are located in the same cabinet as the House Power Transformer is.
The Vehicle transformer primary is supplied with 480VAC directly from the PDU K3 contactor when it is enabled
by the VEH ELEX power switch on the console. The transformers secondary supplies the Vehicles Step-down
Transformer primary with ~ 1Ø 1300VAC.
The TMS (Cage) transformer primary is supplied with 1Ø 480VAC directly from the PDU K4 contactor when it is
enabled by the CAGE ELEX power switch on the console. The transformers secondary supplies the TMS (Cage)
Step-down Transformer primary with ~ 1Ø 1300VAC.
The transformers are each rated at 200KVA and all three transformers are mounted within the Boost Transformer
Housing (transformer coffin), that is typically deck mounted near the Umbilical winch.
Installation and vessel supply voltages can vary significantly from the nominal 3Ø 480VAC that the Millennium Plus
system is designed to operate on. The multi-tapped primaries are intended to allow for matching the transformers
input supply to the installation/vessel supply.
The secondary taps are intended to compensate for the power dissipated (voltage drop) or lost in the Armored Lift
Umbilical and/or Tether.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-15
Millennium Plus System Overview
Use the Oceaneering HV Test Box to ensure that the HPU motor voltage does not drop below the rated motor
voltage (3000VAC) and that the phases are within 5% of each other under full load conditions. See Tech Bulletin
number 145 for additional details on setting the transformer taps.
Secondary Taps
Primary Taps
The Boost Transformer Termination Box is normally mounted to one end of the Boost Transformer Housing and acts
as the termination point for the electrical power deck cables.
Switched electrical power (3Ø 480VAC) from the PDU contactors (K5, K6 & K7) is routed to the Boost Transformer
Termination J-Box, where the connections are made to the primary side of the Boost Transformers. The secondary
side of the transformers is brought back to terminals located in the Boost Transformer Termination J-Box and then
routed through the conduit to the Winch Stationary J-Box (normally mounted to the winch framework; Figure 108).
The Boost Transformer Housing is filled with electrical insulating oil. This oil is necessary for cooling of the
transformers as well as improving their electrical isolation.
The housing should be completely filled with oil without an air gap left in the housing. Air typically contains moisture,
which can condense on the underside of the lid and drip onto the transformers below. The attached compensator
will expand to take up any thermo-expansion of the insulating oil.
6-16 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The filling of the Boost Transformer Housing and compensator should be done when the transformers are as cool
as possible. It is important to ensure that the compensator is completely filed with oil, but left in a flattened state as
it will expand with oil as the transformers heat up in operation.
Note: Do not keep the cover off the transformer housing any longer than is absolutely necessary. The insulating
oil can be easily contaminated by absorbing moisture, limit the time the transformer housing is opened during
inspections and ensure that there are no open vents to the atmosphere.
Boost Transformer
Termination Box Compensator
Air Vent
Boost Transformer
Housing (Coffin)
Oil Block
Conduit to Winch
Stationary J-Box
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-17
Millennium Plus System Overview
The Winch Stationary J-box serves as the termination point for the electrical power conduit from the Boost
Transformer Termination J-box and the termination point for the Fiber Optic deck cable, which are then routed to
the Winch Sliprings.
The Winch Stationary J-box will also contain either the Megacon Voltage Adaptor modules or the DTEC sense
resistors for the TMS HPU, Vehicle Aft and Forward HPUs (depending on the GF system in use).
The Winch Stationary J-box is normally mounted to the framework of the systems winch.
Figure 108 shows the Winch Stationary J-box mounted to a Dynacon Winch, but the actual location can vary
depending on the make and model of the winch system used or the location where the winch is installed.
6-18 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
HV Fuse
Megacon
Voltage
Adapter
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-19
Millennium Plus System Overview
The Slipring assembly is composed of two smaller sections – electrical sliprings and Fiber Optic Rotary Joints
(FORJs) – bolted together.
6-20 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The electrical portion of slipring assembly (Figure 113) consists of a number of metal rings mounted on an insulated
shaft. Individual brushes are in contact with each of the rings, continually transferring electrical power between the
brushes and the rings as the housing is rotated. Electrical connections are completed through the slipring assembly
by connections from the Winch Stationary J-box to the underside of each ring, then through the contacting brush to
the Winch Rotating J-box, where connections are made to the Armored Lift Umbilical.
Both power and signal sliprings work in the same manner, the major difference between them is in the size of the
brush/ring, the size/shape of the brush and the type of insulator that separates them.
The Fiber Optic Rotary Joints (FORJs) contained within the FO Slipring Assembly serve the same function for the
fiber optic (FO) signals as the electrical sliprings serve for electrical power.
Additional details on the functioning of the FORJ can be found in the Telemetry Overview.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-21
Millennium Plus System Overview
Lift Umbilical
Electro-Optical Core
Conduit from Slipring
Assembly
The Winch Rotating J-box, directly mounted to the winch’s drum flange is the termination point for connections to
the Armored Lift Umbilical.
The steel armoring provides the lifting strength of the umbilical cable. It also protects the internal elements from
mechanical damage. The armor is composed of two bands, an inner and outer band of steel strands; each band is
contra-helically wound around the core. The outer layer of armor is composed of a smaller diameter strands than
the inner layer; this allows the armor to be torque balanced which reduces the rotation characteristic of the umbilical,
helping to prevent hockling of the Lift Umbilical.
The Lift Umbilical electrical conductors and Optical fibers are terminated in the Winch Rotating Termination J-box
(see Figure 114) mounted on the winch drum and at the TMS Umbilical Termination Can mounted on the TMS
(Figures 116 and 117).
6-22 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
GR EEN
C AG E
RED
P WR 2
OR ANG E F IB E R
AF T HP U
B LAC K
P HAS E 3 NAT UR AL
C HAS S IS
B G OUND C AG E HP U Inner Armor Belt
B LUE
P HAS E 3 B LUE
F WD HP U
P HAS E 2 S P AR E
WHIT E
S P AR E B LAC K 8 INNE R
F IB E R DR AIN WIR E S
B LUE
F IB E R Outer Armor Belt
NAT UR AL B R OWN
C AG E F WD HP U
HP U P HAS E 2 P HAS E 3
Core Jacket
B LUE OR ANG E
C AG E V E HIC LE
P WR 1 P WR 2
OR ANG E
F IB E R B LAC K
C HAS S IS
Y E LLOW G R OUND
AF T HP U RED
P HAS E 2 AF T HP U
P HAS E 1
B LAC K GR EEN
OR ANG E C HAS S IS F IB E R GR EEN
S P AR E G R OUND Y E LLOW
B LAC K S P AR E
F WD HP U F IB E R
NAT UR AL
P HAS E 1
C AG E HP U
WHIT E P HAS E 1
V E HIC LE
P WR 1
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-23
Millennium Plus System Overview
Umbilical Termination
Mechanical Armor Can
Termination
Lift Umbilical
Opto-Electro Core
Conduit to TMS
Electrical Slipring
Connections
to HPU
Water Alarm
Connection
6-24 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
See Figure 120 for location of Transformer in the Cage type TMS.
The center-tapped 120VAC/20A winding provides 120VAC for the TMS’ lights. The 120VAC/10A and 17VAC/20A
windings provide power for the TMS’ electrical systems.
See OII training modules for general information on transformer theory and operation.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-25
Millennium Plus System Overview
This HPU is identical to the HPU used on the Vehicle. Using the same HPU cuts down on the required onboard
spare parts that the system would need to carry.
HPU Motor
Fiber optics and electrical conductors intended for the Vehicle are routed from the TMS Umbilical Termination Can to
the TMS Slipring Assembly mounted in the Tether Drum. After passing through the TMS Sliprings, FO and electrical
connectors are terminated in the TMS Tether Termination J-box, where connections are made to the Tether.
6-26 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
Optical Fiber
Connections
Tether Connection to Vehicle
Tether
Electrical
Connection
Conduit to TMS
Tether Connection Slipring
Figure 122: TMS Tether Termination Can, Cover and Wiring Removed
Note: To conserve space, FO connectors are mated with free-floating female sleeves and coiled around the interior
of the Tether Termination Can, rather than in FO couplers that are mounted on stand-offs as in other
termination cans.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-27
Millennium Plus System Overview
6.17 Tether
The Vehicle’s flying tether is a flexible, lightweight 30mm diameter cable that provides electrical and FO links to and
from the vehicle.
The Tether is terminated in the TMS Tether Termination Can (Figure 123) and in the Vehicle Tether Termination Can
(Figure 125).
Tethers from different manufactures have been used, having different internal construction. Consult manufactures
data sheet for details on your supplied Tether.
Tether Entry
High Voltage
Terminal Strips
Fiber Optic
Couplers
Low Voltage
Terminal Strips
Electrical Tubing
Connections for
Transformer Can
and HPU Motors
6-28 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
The center-tapped 120VAC/20A winding provides 120VAC for the Vehicle’s lights. The 120VAC/10A and 17VAC/20A
windings provide power for the Vehicle’s electrical systems.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 6-29
Millennium Plus System Overview
This HPU is identical to the HPU used on the TMS. Using the same HPU cuts down on the required onboard spare
parts that the system would need to carry.
The motors are coupled to the Vehicle Termination Can by use of oil-filled Tygon tubing connected together with
PBOF (pressure balanced oil-filled) connectors.
Fwd HPU
Motor
Aft HPU
Motor
See OII training module #108 for an overview of 3Ø (three-phase) motor theory.
6-30 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Section 7:
Telemetry Overview
Telemetry Overview
Section Contents
7.0 Telemetry Overview ......................................................................................................................................7-1
7.1 Millennium Plus Telemetry Functional Overview ......................................................................................7-3
7.2 OPAC Stacks ...........................................................................................................................................7-7
7.2.1 Surface OPAC Stack ......................................................................................................................7-7
7.2.2 TMS OPAC Stack ...........................................................................................................................7-9
7.2.3 Vehicle OPAC Stack .....................................................................................................................7-10
7.3 Control, Telemetry, and Graphics (CTAG) .............................................................................................. 7-11
7.4 RabbitCore Firmware ............................................................................................................................. 7-11
7.5 Fiber Optic Multiplexer (FO Mux) ...........................................................................................................7-12
7.6 TMS Medium-Speed FO Mux ................................................................................................................7-16
7.7 High-Speed FO-Mux Used for the Vehicle .............................................................................................7-19
7.8 Fiber Optic Transmission Path ...............................................................................................................7-21
7.8.1 Fiber Optic Sliprings .....................................................................................................................7-22
Millenium Plus System Overview
The Telemetry System used in the Millennium Plus (as well as most other OII ROV systems) is composed of a group
of individual component subsystems that have been combined to form what we call the telemetry system.
To simplify the description, it is assumed that the reader understands that a ‘complete’ telemetry system also
requires input devices such as Joysticks, on/off switches, function switches, gyros, oil level sensors, pressure
sensors, depth and heading sensors etc., as well as output devices such as Proportional Power Controllers (Lamp
Controllers), Proportional Valve current drivers, solenoid drivers, relays etc.
While these devices are necessary for a real functional telemetry system, for the purpose of this simplified overview
the description will be limited to the systems involved in the transmission and reception of data. Peripheral devices
are covered by related maintenance manuals and by the associated Manufactures data sheets.
The following subsystems are combined and act as one overall Telemetry system:
• Three individual OPAC (Oceaneering Power and Control) Stacks; the Vehicle, TMS and Surface (Console
Pilot Tray or Pilot Chair) contains an OPAC stack (node).
• Two independent FO Muxes (Fiber Optic Multiplexer); one set is used to link the surface with the vehicle
and a second set is used to link the surface with the TMS.
• CTAG (Control, Telemetry, And Graphics) software; running on the Pilot and Aux computers. (Note: some
systems may be configured with a Pilot Computer running DOS CTAG and a Server running CTAG for
Windows (CFW)).
• RabbitCore firmware running in each OPAC Stack node.
• Fiber Optic transmission path; consisting of Single Mode (SM) glass fibers contained within the deck cables,
Lift Umbilical, Tether and the FO Slipring Assemblies in the Winch and TMS.
It is important to understand the distinction between the OPAC stacks and the FO Muxes. The OPAC stack at
each node acts as a data acquisition and control device. Under the control of CTAG, the nodes pass data between
each other. Such data includes commands from the Pilot and feedback from sensors. The FO Mux forms a bridge
between these nodes and allows them to be separated by large distances. It achieves this by converting the data
signals to a serial optical data stream and transmitting them over optical fibers.
Like the OPAC stacks, the FO Muxes are multiplexer systems in their own right. In addition to handling data
flow between the surface and subsea OPAC Stacks, they also handle other data streams, such as data links for
Sonar, SC Manipulators, Tooling-RCU, Gyro, Paro, Video, etc. Together, the OPAC stacks and FO Muxes form the
Millennium Plus Telemetry System.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-1
Millennium Plus System Overview
The block diagram in Figure 127 illustrates the Millennium Plus telemetry system in its most basic form.
CONSOLE ANALOG
OPAC STACK DIGITAL
PILOT COMPUTER
VIDEO VIDEO
TMS VEHICLE
ANALOG CONSOLE FO MUX CONSOLE FO MUX ANALOG
DIGITAL DIGITAL
OPTICAL
FIBER
Note: It is important to understand that the FO Mux is ‘transparent’ to the OPAC subsystem data streams and
the TMS/Vehicle video. In other words, what you put in at one end of the FO Mux, you get back out at the
other end.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-2
Millenium Plus System Overview
CTAG CTAG
Pilot Computer Aux Computer
RS-232
Sonar
Vehicle Telemetry RS-232 DIGITAL
RS-232 / RS-422
T-RCU
RS-422
SC Manip. I/O
CONVERTER
PILOT CHAIR
RS-232
TOUCH SCREEN
VEHICLE
High Speed FO Mux
PILOT CHAIR
RS-232 (Focal 903)
OPAC (Console Module)
TMS Telemetry
RS-232
WINCH SLIPRING
VIDEO
Analog and Digital I/O
OUTPUTS
RS-232
RS-232 / RS-422
CONSOLE RS-422
CONVERTER
DIGITAL
OPAC I/O
RS-232
(PILOT TRAY)
TMS
Med. Speed FO Mux
VIDEO
OUTPUTS
Note: Figure 128 shows both the Pilot chair and the Console OPAC. A system will have one or the other installed,
not both.
Note: If a Pilot Chair is present in the system, there will be also be installed a separate, dedicated RS-232 data
link from the Touch Screen to the Pilot Computer Fastcom port 1-6. This Fastcom port is not utilized if a
Pilot Chair is not installed.
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7-3
Millennium Plus System Overview
VEHICLE
OPAC
I/O
Term Can VEHICLE
MB-88
Fiber High Speed FO Mux
RS-232
(Focal 903)
(Remote Module)
MB-88
RS-232
TETHER
Fiber
VIDEO
INPUTS Relay Brds
Cam/Survey
Controls
TMS
SLIPRING TMS TELEMETERY CAN
DIGITAL
TMS TMS
UMBILICAL
I/O
Fiber TMS
TERM Med. Speed FO Mux OPAC
CAN
(Focal 903)
(Console Module)
VIDEO
INPUTS
Surface Description
At the surface, the OPAC stack in the Console Pilot Tray or in the Pilot Chair (depending on which one is installed)
collects analog/digital command inputs such as the Pilot’s joystick commands, lamp intensity or function commands
(such as enabling/disabling an auto-controller) and then converts these inputs into a serial digital form. After
conversion, the digital data is transmitted (via a RS-232 data link) to the Pilot Computer (Fastcom-1-7) for processing
by CTAG. If there is a Pilot Chair installed, touch screen commands will be sent to the Pilot Computer (Fastcom-1-6)
on a separate RS-232 data link.
After passing through CTAG’s data processing, two separate OPAC telemetry data streams (RS-232) are created
and outputted from the Pilot Computer. One intended for the Vehicle FO Mux (Fastcom-1-1) and the other one for
the TMS FO Mux (Fastcom-2-1).
If the system is using a Pilot Tray instead of a Pilot Chair, the vehicle and TMS telemetry RS232 streams are routed
back to the Pilot Tray, converted into RS422 format, and then sent to the FO Muxes (see Figure 128). This is done
in order to keep the Pilot Trays backwards-compatible with older system that may have their FO Muxes mounted in
the winch (note that the R232/RS422 converters may be bypassed or removed in some systems).
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-4
Millenium Plus System Overview
While the two Focal FO Muxes are similar in many respects, there are some major differences between them. First,
understand that they are completely separate FO Muxes and operate independently of each other (see Figure 127
and Figure 128).
The TMS FO Mux (console module) is a medium-speed FO Mux that can transmit/receive up to eight serial data
channels and receive up to four composite video signals.
The Vehicle FO Mux (console module) is a high-speed FO Mux capable of transmitting/receiving up to 16 serial data
channels and receiving up to eight composite video signals.
After receiving their TMS and Vehicle telemetry RS-232 data streams, the FO Muxes combine (multiplex) the OPAC
data stream from the Pilot Computer with any other data streams (such as the Sonar data link or the Tooling-RCU).
The FO Mux then converts the combined data streams into an optical beam that is inserted into one of two optical
fibers (F1/F2, primary and secondary fiber; user or auto selectable) in the fiber optic deck cable.
The fiber optic deck cables are routed to the Winch Stationary J-box, then coupled through the rotating winch drum
by the FO Slipring Assembly into the Winch Rotating J-box, where the optical fibers are connected to the Armored
Lift Umbilical.
Each Console Mux (TMS or Vehicle) communicates with its subsea counterpart via a single optical fiber. There is
however two fibers connected between each pair of muxes, two fibers are used in order to provide a redundant
backup fiber. Should the primary fiber fail, the Console FO Mux can automatically switch over to the backup fiber.
The Remote (subsea) FO Mux is permanently connected to both fibers and employs a 50/50 splitter to transmit/
receive data simultaneously on both, so manual fiber switching is not required.
The fiber select switch on the FO Mux can be manually selected to F1, F2 or Auto. When the Auto switch position
is selected, the FO Mux will select the lowest loss fiber connection between the two fibers and use that one as
the ‘primary’ fiber. Should the selected fiber fail or increase its loss, the FO Mux will automatically switch to the
secondary fiber.
While the idea of an auto fiber backup is a good one, be aware that when the Vehicle/TMS FO Mux is powered
down, the auto fiber switch will cycle between the two fibers seeking a ‘good’ fiber. This continuous switching can
damage the fiber switch.
It is recommended the FO Mux Auto Switch position is not used. Select either F1 or F2 and leave the switch in
that position. Remember that the FO Mux will not automatically switch to the backup fiber, if the primary fiber fails.
Manually switching the FO Mux to the backup fiber should be the first troubleshooting step you take if you begin
having telemetry problems.
Subsea Description
The armor on the Armored Lift Umbilical is mechanically terminated in the TMS Bullet. The electrical/optical core
of the Lift Umbilical is routed to the TMS Term Can, where the electrical and optical fibers are split out from the
umbilical core and routed either to the TMS or to the Vehicle.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-5
Millennium Plus System Overview
Fibers intended for the TMS are sent to the TMS Telemetry Can where the fibers are received by the TMS FO Mux
(Remote Module). The TMS FO Mux converts the received optical beam back into an electrical serial data stream,
separates the previous multiplexed data streams back into the various individual data streams. The TMS Telemetry
data is sent to the TMS OPAC Stack. Any other data streams are outputted on its assigned survey connecter
mounted to the Telemetry Can penetrator head.
Fibers intended for the Vehicle are routed first through the TMS FO Slipring Assembly, then into the Rotating J-box
where the fibers are connected to the Vehicle flying Tether. The Tether is terminated in the Vehicle Term Can; fibers
are routed to the Vehicle FO Can where they are received by the Vehicle FO Mux (Remote Module).
The Vehicle FO Mux converts the received optical beam back into an electrical serial data stream, separates the
previous multiplexed data streams back into the various individual data streams. The Vehicle Telemetry data is sent
to the Vehicle Telemetry Can where it is received by the OPAC Stack.
Any other data streams are outputted on its assigned survey connecter mounted to the end bell of the FO Can.
The receiving OPAC Stack, in both the Vehicle and TMS operate in a similar fashion. The receiving OPAC Stack
reconverts the Vehicle/TMS Telemetry data back into the analog/digital commands needed by the Vehicle/TMS sub-
systems to perform the function commanded by the Pilot.
Aside from the various Power Supplies, both the TMS and Vehicle Telemetry Cans contain additional PCBs that are
required to turn the OPAC analog and digital outputs into a command function:
• Proportional Power Controller (PPC); provides a variable 120VAC to each lamp circuit.
• Gyro/Compass Data Switcher PCB; switches Gyro/Compass data, allows either to be the primary heading
source while the other is the backup.
The Vehicle/TMS OPAC Stacks also collect system inputs such as water alarms, hydraulic oil levels, power supply
voltages, etc. and then sends these inputs back to CTAG for processing (auto-controller loops) and/or graphics
display.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-6
Millenium Plus System Overview
The primary function of each OPAC Stack (called a ‘stack’ due to the way in which the PCBs are packaged) is to
collect or output digital and analog signals. Each OPAC Stack deals only with the gathering and/or outputting of
analog and digital signals in its respective section of the Millennium Plus System and is configured for the location
in which it is installed.
Pilot Tray, TMS and Vehicle OPAC Stacks are shown in Figure 130, Figure 131, and Figure 132 respectively. The
OPAC Stacks shown are typical arrangements of OPAC PCBs in each of those locations.
Each OPAC stack contains the same basic components, stacked in layers; a Control PCB, a Power Supply PCB
and several I/O Backplane PCBs, which contain various daughter cards, referred to as I/O Modules.
The OPAC Control PCB contains a software jumper that configures the Rabbit processor firmware and it must be
correctly set for the node in which the Control PCB is installed.
In addition, each I/O Backplane must be correctly configured with the proper I/O Modules and have its address
jumpers set correctly. The I/O Backplane PCBs are identical, so the jumpers configure them for the layer in which
they are situated.
See the OPAC Manual and Millennium Plus Technical Manuals for additional details on module configurations and
jumper settings.
Note: The OPAC Stack layers are always numbered from the bottom up, i.e.; the Power Supply Module is always
A1; the next PCB will be A2, then A3, A4 up to the max of A5. Depending on the stack configuration, the
Control PCB will be either A5 (Vehicle) or A4 (Surface and TMS) depending on the number of PCBs in the
stack.
Note: Currently, all I/O Backplane PCBs are loaded with three I/O Modules. Care should be taken to ensure that
the proper module is installed on the correct I/O Backplane PCB, as a wrongly-placed module could
produce unpredictable results.
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7-7
Millennium Plus System Overview
A3 - I/O Backplane
A4 - Control PCB
A2 - I/O Backplane
Note: The OPAC Stack shown in Figure 130 is taken from a Pilot Tray. The OPAC Stack in the Pilot Chair is identical,
except that the stack uses a vertical orientation.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-8
Millenium Plus System Overview
A4 M1 - Rabbitcore Module
A1 M2 - Telemetry Board
A4 - Control PCB
A3 - I/O Backplane
A2 - I/O Backplane
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-9
Millennium Plus System Overview
A5 M1 - RabbitCore Module
A5 - Control PCB
A5 M2 - Telemetry Board
A4 - I/O Backplane
A3 - I/O Backplane
A2 - I/O Backplane
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-10
Millenium Plus System Overview
The Pilot Computer is the primary computer and performs all of the data processing. The Aux computer is synchronized
to the Pilot Computer and is used primarily to provide independent access to the various soft switches, diagnostic
and operating displays. It also acts as a backup in the event of the Pilot Computer failing.
Consult The CTAG manual for addition details on the CTAG software.
Ordinarily, the operator of an OPAC Stack doesn’t interact with the RabbitCore software, but there are a few points
that the technician should be aware of in regards to the RabbitCore software:
• Each OPAC node (Console, TMS or Vehicle) contains an identical version of OPAC firmware. A set of
jumpers on the Control PCB tells the firmware which node it is controlling. It is therefore vital that the
firmware jumpers are set correctly for that particular node.
• Each I/O Backplane has three address jumpers that determine which level of the stack the I/O Backplane
resides on. The jumpers must be correctly set to enable the RabbitCore processor to communicate with the
I/O Modules on a particular I/O Backplane.
• The RabbitCore firmware resides in flash memory and can be upgraded through a CTAG download or
offline with a standalone cable connected directly to the Rabbit Module.
Note: Each I/O Backplane PCB has a required and specific set of I/O Modules that must be installed on it when it
is installed into a specific level (A2 to A4) of a specific node (Surface, TMS or Vehicle OPAC Stack). See the
OPAC manual for additional information.
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7-11
Millennium Plus System Overview
The FO Mux (currently, the Focal 903) used in the Millennium Plus System is actually two independent FO Muxes.
A Medium-speed Focal 903 FO Mux is used for the surface to TMS data link while a Focal 903 High-speed FO Mux
is used for the surface to Vehicle Link.
The FO Mux utilizes the principles of Wave Division Multiplexing (WDM) to transmit up traffic and down traffic on a
single fiber. The console module transmits laser light at a wavelength of 1550nm, while the remote module transmits
light at 1310nm. Light transmitters and receivers at each end are therefore configured to operate at different
wavelengths (Rx at the remote is 1550nm and Tx is 1310nm, while the console unit is opposite). Transmitters and
receivers are connected to a single fiber via a WDM device. A fiber splitter then replicates the data stream on two
separate fibers in order to provide redundancy.
S T -S T
TX ST
F IB E R
1550 nm WDM S WIT C H
RX S T -S T ST
1310 nm
S T -S T
S M F IB E R
S M F IB E R
R E MOT E MODULE
S T -S T
RX
S P LIT T E R W DM 1550 nm
S T -S T TX
1310 nm
S T -S T
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7-12
Millenium Plus System Overview
Some of the terms used by Focal in their technical manuals can cause confusion, so it would be useful to explain
the Focal terminology.
The surface FO Mux is called the ‘console module’ and the FO Mux in the TMS or Vehicle is called the ‘remote
module’. Additionally, the remote modules are also referred to as HD, meaning ‘High Density’. The HD term denotes
the fact that the remote modules are designed to be as compact as possible, in order to fit in the limited space
afforded by one-atmosphere pressure vessels.
The remote module (see Figure 136 and Figure 138) is a combination of HDB-TX and FMB-VTX cards. Each
HDB-TX card supports 4 composite video inputs, 4 dedicated RS-232 data channels and 4 channels that can be
configured for a variety of data formats (RS485, RS422, Arcnet etc.) using adaptable interface board (AIB) plug-in
daughter modules. The video input “SMB” connecters are on the front of the board, while the serial data ‘WAGO’
connectors are mounted on a separate panel (also called a data box) that connects to the HDB-TX board by a
ribbon connector. LEDs adjacent to each WAGO connector indicate the presence of Tx and Rx data. Medium speed
(TMS) remote muxes have only one HDB-TX card, while high-speed (Vehicle) muxes have two, thereby doubling
the capacity.
The FMB-VTX card multiplexes all the data/video channels to a single serial data stream and transmits it
simultaneously on two separate optical fibers to the console module. LEDs on the front panel indicate the presence
of a video signal on the HDB-TX input connectors. A separate “Link” LED indicates a good optical link between
console and remote modules.
As space is not a constraint on the surface, the console module (see Figures 135 and Figure 137) features separate
VIB-RX and AIB cards for video and data respectively. Each VIB-RX video output board outputs 4 channels
of composite video on front panel-mounted SMB connectors. Each AIB provides 4 data channels that can be
configured for a variety of data formats using AIB plug-in daughter modules. Connections to the AIB are via front
panel-mounted WAGO connectors. LEDs adjacent to each WAGO connector indicate the presence of Tx and Rx
data. Medium speed (TMS) console muxes have one each VIB-RX and AIB cards, while high-speed (Vehicle)
muxes have two, thereby doubling the capacity.
The FMB-VRX card receives the optical data from the remote module, de-multiplexes the data/video channels
and routes them to the VIB-RX and AIB cards. It monitors the identical data streams from each of the two fibers
connected to it and automatically selects the fiber with the strongest signal. It then uses this fiber to transmit the
downlink data to the remote module. LEDs on the front panel indicate the reception of video signals from the remote
module. A separate “Link” LED indicates a good optical link between console and remote modules.
The High and Medium-speed names refer to the data rate at which the FO Mux transmits data. The High-speed FO
Mux operates at a higher data rate, which equates to a higher bandwidth, which in turn means that more data can
be transmitted by the device.
The downlink speed in both muxes is the same at 172 Mb/sec. The uplink speed for the medium-speed FO Mux is
687 Mb/sec and the High-speed FO Mux is 1.375 Gb/sec. The reason for the bandwidth difference requirements is
primarily the video channels that each FO Mux supports; the High-speed FO Mux can handle up to eight composite
video inputs, while the Medium-speed FO Mux can only handle four composite video inputs.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-13
Millennium Plus System Overview
Due to the downlink being limited to data only, the 172 Mb/sec downlink is more than sufficient to send the data.
Both FO Muxes use the same video and data boards; the High-speed FO Mux doubles the number of boards to get
twice the number of video and data channels.
Note: Focal uses the terms Adaptable or Analog Interface Board interchangeably when referring to the AIB
PCB. This is because the AIB will accept a variety of both analog and digital plug in modules.
DATA DATA
I/O I/O
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7-14
Millenium Plus System Overview
WAGO Connector
Data Link LED
Fiber Selector
Switch
Power Supply
Optical ST
Connector
Note: The green LINK LED will light when the 1310nm uplink is established and the Active Video LEDs will light up
to indicate active video sync pluses present (NTSC or PAL).
WAGO Connectors
1 to 4 Functions, Depending
Active Video LEDs on the Installed Module
WAGO Connectors
5 to 8 are Dedicated to
Data Link LED
RS-232 Only
RX Data LED
TX Data LED
Video SMB
Connector
Optical ST
Connector
VIB-A PCB
VIB-B PCB
Note:The green LINK LED will light up when the 1550nm downlink is established and the Active Video LEDs will
light up to indicate active video inputs.
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7-15
Millennium Plus System Overview
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7-16
Millenium Plus System Overview
DIAGNOSTIC
PORT
Ch 1
Power Switch
+12V
Ch 2 VIB-A
VIB-B
1 2 3 4
Ch 3 F1 LINK
AUTO -12V
Ch 4 F2
FMB-VRX
Can be a mix of
(Fiber Optic
different data
Multiplexer Board)
formats
The TMS Medium-speed FO Mux (console module) consists of a five-slot backplane allowing the following PCBs
to be plugged in to it:
• One Fiber Multiplexer Board (FMB or FO MODEM).
• One video output board (VIB-RX).
• One RS-232 interface board (AIB filled with RS-232 plug-in modules).
• One Adaptable (Analog) Interface Board (AIB filled with a variety of plug-in modules).
• Power supply. In addition, a power on/off switch is mounted on a front panel.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-17
Millennium Plus System Overview
Digital Breakout
Panel
Video
In
1 VIB-A HDB-TX - B
VIB-B T R T R
2 1 2 3 4
1 5
3
LINK
HDB-TX #1 4
(Video In and 2 6
Data I/O)
3 7
DATA
I/O
4 8
RS-232
The 903 medium-speed remote FO Mux consists of two boards only, plus a breakout panel (also called a data box)
for the digital I/O connectors. The boards are one FMB and one HDB-TX video/digital input board.
The HDB-TX boards have video connectors on the front panel; the data I/O panel (box) that connects to the HDB-
TX board via a ribbon cable.
Be aware that each HDB-TX board has four built-in RS-232 channels and four adaptable (plug-in) modules.
Consequently, the console module must always contain at least one AIB that is loaded with RS-232 modules (or
empty for unused channels). The second AIB can have a variety of modules installed, but must have matching
modules (or empty for unused channels) installed in the HDB-TX board in the remote module.
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7-18
Millenium Plus System Overview
DIAGNOSTIC
PORT
Ch 1 Ch 1
+12V
Ch 2 Ch 2 VIB-A
VIB-B
1 2 3 4
Ch 3 Ch 3 F1 LINK
AUTO -12V
Ch 4 Ch 4 F2
The surface High-speed FO Mux (console module) consists of a seven-slot backplane, allowing the following PCB
to be plugged in to it:
• One Fiber Multiplexer Board (FMB or FO MODEM)
• Two video output boards (VIB-RX)
• Two RS-232 interface boards (AIB filled with only RS-232 plug-in modules)
• Two Analog/Adaptable Interface Boards (AIB filled with a variety of plug-in modules)
• Power supply; in addition, a power on/off switch is mounted on a front pane
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-19
Millennium Plus System Overview
Connected to HDB-TX
PCBs by internal
Ribbon Cables
Data I/O)
3 7 3 7
DATA DATA
I/O I/O
4 8 4 8
RS-232 RS-232
The 903 High-speed Vehicle FO Mux (remote module) consists of three boards only, plus a breakout panel for the
digital I/O connectors. The boards are one FMB and two HDB-TX video/digital input boards.
The HDB-TX boards have video connectors on the front panel; the data I/O panel (box) connects to the HDB-TX
board via a ribbon cable.
Be aware that each HDB-TX board has four built-in RS-232 channels and four adaptable (plug-in) modules.
Consequently, for each of the HDB-TX boards installed in the remote module, the console module must contain
at least one AIB that is loaded with RS-232 modules (or empty for unused channels). The second AIB can have a
variety of modules installed, but must have matching modules (or empty for unused channels) installed in the HDB-
TX board in the remote module.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-20
Millenium Plus System Overview
Despite the higher costs and complexities involved in using fiber optics, they offer some major advantages over
electrical data formats in deep water (long distance) systems:
• High bandwidth/Low signal loss; fibers are capable of carrying optical signals for distances exceeding
40,000ft (12,000m) with little loss or signal degradation.
• Immune to electromagnetic interference.
• Physically smaller than electrical conductors, allowing multiple fibers to be carried in the space of a few
TWPs (twisted wire pairs).
Glass optical fibers are made of high-quality silica glass and each individual fiber consists of three distinct parts:
• Core; thin glass center of the fiber where the light travels.
• Cladding; outer optical glass layer surrounding the core that reflects the light back into the core.
• Buffer coating; plastic coating that protects the fiber from damage and moisture.
FO fibers are used through out the Telemetry System and are found in a number of different forms depending on
their use; bare plastic buffered fibers, patch cables, optical deck cables, individually armored fibers or multiple fibers
contained within a protective steel tube.
Optical fibers, by their very nature are delicate and can be easily damaged and generally require some form of
additional protection depending on their intended use. Patch or deck cables use Kevlar strain relief and plastic
jackets, Lift Umbilicals and/Tethers, may use different protective schemes such as individually armoring the fibers
(Rochester Optical Steel-Light®) or grouping multiple fibers within a steel tube (as used by Nexans in their tether
and umbilical products).
Where exposed bare fibers are used in the Vehicles FO Can, TMS Telemetry Can or internal fibers within the FO
Mux, extreme care must be used in handling and securing the fibers to prevent damage or kinking of the fibers.
See OII Technical Modules 043 and 130 for additional information on FO theory and fiber optic cable construction.
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7-21
Millennium Plus System Overview
Note: The FO Slipring Assembly in the TMS is oil-filled and pressure compensated through the TMS’ compensation
system. The FO Slipring Assembly in the Lift Umbilical Winch is not oil-filled or compensated.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-22
Millenium Plus System Overview
The Fiber Optic Rotary Joints (FORJs) serve the same function for the fiber optic (FO) signals as the electrical
sliprings serve for electrical power.
The operation of the FORJ is fairly straightforward; Figure 145 shows the internal view of a typical FORJ. The FORJ
assembly is composed of several stacked independent single passes.
As the winch drum rotates, the torque arm (shown in Fig 143) on the front of the Slipring assembly locks down the
center section of each FORJ, keeping it stationary relative to the rotating drum, while the housing portion rotates
with the winch/Tether drum.
The gear train (Figure 145) ensures that each of the independent single FORJ passes remain synchronized and
rotate together; otherwise the internal fibers would break when the FORJ was spun. Only two passes are shown in
this drawing, but additional units can be stacked together to allow for more FO passes in a slipring assembly.
Collimator Lenses
Stationary portion of
FORJ
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7-23
Millennium Plus System Overview
Each optical fiber is routed through the sliprings center tube to a separate FORJ assembly, where they are connected
to a collimator lens (beam expander) which greatly expands the diameter of the beam; the widened beam is then
reflected off a magneticly-coupled 90º mirror that rotates along with the housing. The 90º mirror is aimed at an
objective lens (second collimator lens) which refocuses the beam and inserts it back into the optical fiber.
Note: See OII Technical Module 117 for additional information on the FO Slipring Assemblies.
Note: Fibers routed to each of the FORJ sections will pass through each of the collimated (expanded) beams as the
slipring assembly is rotated. There will be some small optical loss associated with the fiber passing through
the beam, but the losses are typically small, less than .1db, due to the collimated beam being much wider
than the interfering fiber.
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
7-24
Section 8:
Index
(This Page Intentionally Left Blank)
Millennium Plus System Overview
fiber optic
I
terminations 4-7
in-line hydraulic components 5-28
transmission path 7-21
fiber optic (FO) can 5-12, 5-15, 7-21 J
fiber optic multiplexer (MUX) 7-12 joystick, vehicle 3-13
fiber optic rotary joints 4-10, 6-21, 7-23
L
internal view (diagram) 7-23
LARS
fiber optics 1-1
see Launch and Recovery System
fiber optic sliprings 7-22
Launch and Recovery System
flying tether 4-5, 4-8
power requirements of 2-1
FMB-VRX card 7-13
weight of 2-1
FMB-VTX card 7-13
lead ballast 5-7
foam block
tray 5-7
definition of 5-5
lighting system 5-35
foot pedal 3-13
lockout/tagout 4-7, 5-8, 6-10, 5-9
FORJ
high-voltage components 6-1
see fiber-optic rotary joints 4-10
motor housing 4-9, 5-10
frame, vehicle 5-4
power tray main supply breaker 3-4
G tether termination can 5-8
GFI selector switch 3-6 transformer can 5-9
ground fault interruption system (GFI) 3-2 umbilical termination can 4-7
of the Pilot Console 3-3 LOTO
ground fault monitoring 3-3 see lockout/tagout
ground fault resistance meter 3-6
M
H manipulators 2-2, 5-35
HDB-TX board 7-18, 7-20 Megacon GFI module 6-5, 6-19
high pressure oil filter 4-15, 5-23 Megacon GFI Panel 3-3, 3-4
house power transformer 6-14 Millennium Plus system
HPU control console 3-1
see hydraulic power unit overview of 1-1
HPU boost transformer 6-15 power requirements of 2-1
HPU motor data plate 4-16 specifications of 2-1
hydraulic oil reservoir 4-15, 5-22 telemetry system of 7-1
hydraulic power unit 2-1, 4-15, 4-16, 5-20 weight specifications of 2-1
definition of 6-26 motor stator housings 5-8
hydraulic pressure gauges 5-27
8-2 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
N power requirements
Navigation (or Navigators) Console 3-2, 3-10 of the Millennium Plus system 2-1
pressure relief valve 4-15
O pressure-tolerant can 4-11, 4-12, 4-13, 5-7, 5-12
oil compensation system 5-25 pressure transducer can 5-12
oil-filled cables 4-9, 5-8, 5-11 proportional control unit 4-15, 5-8, 5-29
oil-filled cans (housings) 4-6, 5-8 propulsion system 5-32
OPAC stack 3-13, 4-12, 7-1, 7-7
o-ring sealed connectors 4-9 R
RabbitCore processor 7-11
P rate control unit 4-13, 4-15, 5-8, 5-31
PBOF connectors 4-9, 5-10 RCU
PCU see Rate Control Unit
see proportional control unit responder/transponder 5-35
penetrator end cap 4-13 roller-carriage assembly 5-13
pilot chair 3-2, 3-11 rotating J-box 4-8, 6-21, 6-27
and DTEC GFI 6-7 definition of 6-22
and Megacon GFI 6-7 RS-232 3-11, 3-13, 7-18, 7-19, 7-20
OPAC stack of 3-13 linking the pilot and auxiliary PCs 3-9
touch-screen display of 3-12
Pilot Console 3-2, 3-3 S
auxiliary (aux) PC of 3-9 seat adjustment motors 3-13
power controls
of the Pilot Console 3-3
power distribution unit 6-3, 6-9
internal components 6-12
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 8-3
Millennium Plus System Overview
telemetry can 4-12, 4-13, 4-14, 5-12, 5-13, 7-21 definition of 6-25, 6-29
8-4 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.
Millennium Plus System Overview
W
water alarms 4-13, 5-14
winch sliprings 6-20
internal electrical view 6-21
winch stationary termination J-box 6-18, 7-22
workshop container
power requirements of 2-1
weight of 2-1
© Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc. 8-5
Millennium Plus System Overview
8-6 © Oceaneering International, Inc. 2009. All rights reserved. OCEANEERING® is a registered trademark of Oceaneering International, Inc.