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Chapter 6 Robot Battery Systems: Pumper Battery

CHAPTER 6

Robot Battery System

PUMPER ROBOT BATTERY

The battery in the robot is a rechargeable sealed lead-acid Gel type battery

12 Volt

31AH

. This type of battery is very dependable and safe. It can be repeatedly charged and

discharged.

Installing and Removing

When removing and inserting the battery in the robot battery compartment, slide the

battery in and out carefully.

Always fasten the battery down snug with the strap

provided.

It is best to remove the robot battery when transporting the robot particularly if

the body may be on its side or upside down during shipment.

How to Recharge

To recharge the robot battery, first open the trunk hatch and unplug the battery from

the main component board. Next connect the charger wire to the battery. Finally connect
the line cord of the charger into a 110 volt AC outlet. Leave the trunk cover off or open
during charging for ventilation. The robot is supplied with an automatic type battery charger.
This will recharge the battery full in 10 to 14 hours. This type of charger will not overcharge
the battery if left "ON" indefinitely. Avoid leaving it charging for more than 5 days. Generally
remove the battery from the charger when the charger indicates a full charge.

Cautions

!

Batteries are provided with a polarized connector to avoid connecting the battery

backwards and damaging the robots circuitry. If these connections are disturbed, please be
careful to observe proper polarity when reconnecting the battery. Use a digital voltmeter, if
necessary to verify polarity of the battery and at the end of the connector of the battery.

It is best not to allow the robot battery to go completely dead as this shortens the life

of the battery and makes recharging more difficult.

Fully charge the battery after each

use.

More charging instructions are in the charger section

Important

:

Charge the battery to a full charge right after using the robot. Gel

type batteries will be damaged if not kept fully charge at all times.

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Summary of Contents for Patches & Pumper

Page 1: ...i Patches Pumper Robot Operating Manual Version 6C ...

Page 2: ... that you can easily expand its functions making its usefulness grow as your needs grow Please read this manual carefully It will help you make the most of your robot Attention to maintenance will greatly prolong the life of your robot Most problems you encounter will be minor and the manual will provide an answer Please feel free to contact us if you have unanswered questions relating to operatio...

Page 3: ... Option 13 Chapter 3 Voice System Overview 14 Location of Voice Units 14 Belt Transmitter 15 Robot Receiver 16 151 System Robot TX and Belt 151 Receiver 17 Voice System Troubleshooting 18 Mouth Operation 20 Operator s Voice Headset Transmitter and Receiver 21 Chapter 4 Cassette Tape Player System 22 Cassette Tape Player Instructions Diagrams 23 Chapter 5 Siren 25 Chapter 6 Robot Battery Systems 26...

Page 4: ...ot Parts Identification 48 Lower Robot Top View 49 Lower Robot Bottom View Motor Pulley Set Screws 50 Main Electronics Box 51 Pumper Main Electronics Board 52 Pumper Fuse Block Detail 53 Patches Head Inside View 54 Eyes Servo Board 55 Upper Robot Bottom View 56 Patches Control Board 57 Notes Section 58 Technical Tips Section 59 These sections can be used to place additional notes that you would li...

Page 5: ...onal shipping charges In no event shall ROBOTRONICS Inc be liable for any incidental or consequential damages in connection with or arising from the use of the robot If You Have A Problem 1 Call our service department and explain the problem The phone number is 801 489 4466 Most difficulties are minor and can be solved easily over the phone If possible have the robot near the phone when you call I...

Page 6: ...rization number before sending a part or your robot in for repair or modifications The staff of ROBOTRONICS has taken due care in preparing this manual Because of parts availability robots may vary slightly from unit to unit If you have any questions please contact our service department The service department phone number is 801 489 4466 The buyer is further responsible to ensure that proper and ...

Page 7: ... to be avoided Safe clearance should be maintained between these obstacles and the robot The robot should not be operated near stairs When operating on a stage you should leave plenty of distance between the robot and the edge of the stage and should keep the area below the stage clear of anyone Never leave the robot ON when unattended or in direct sunlight for extended periods of time The robot i...

Page 8: ...obot on the lower robot body 2 Locate the four body latches and push the pins into the body to secure the upper robot to the lower Two of the latches are located in the compartment where Patches sits The pins are to the left and right of Patches The other two are at the back of the robot To latch these you will need to reach in through the back hatch trunk 3 Connect the 37 pin connector which is a...

Page 9: ...per operation The robot is now ready to operate Step 8 Powering Down 1 Turn off the voice equipment on your belt 2 Turn the robot power switch to the OFF position 3 Turn off the RC unit Step 9 Charge the batteries again Connect the Pumper battery to the charger and bring it back to a full charge before leaving the robot This battery should not be left with a partial charge The transmitter battery ...

Page 10: ...here are four latches that must be latched to secure the upper robot to the lower robot See the diagram below These pins must be pushed in to secure the upper robot To strap the robot on the cart roll the robot on to the cart with the back wheels first The back wheels will drop in to the recesses Pull the S hooks on the cart up to each of the four eye hooks under the front and back bumpers of the ...

Page 11: ...t held by the operator and the receiver with its associated components in the robot The Radio Control Transmitter converts movements of the control sticks and switches into a coded radio signal which is transmitted by radio to the Radio Control Receiver within the robot The signal is received and then decoded by the microcontroller which is on the main circuit board The micro controller controls f...

Page 12: ...ontal and vertical trim tabs to the left and below the joystick are for centering and should be adjusted if the robot creeps on its own otherwise they should be left in the center The left joystick left and right moves the eye pupils and the head The eyes will look in the direction that you move the head automatically The slider control below the stick should be left in the center so that the eyes...

Page 13: ...r 2 Radio Control System RADIO CONTROL TRANSMITTER Robbe Futaba F 14 1 2 13 12 11 9 8 7 6 5 4 14 Switch bank 1 1 2 3 4 5 6 7 8 Switch bank 2 1 2 3 4 5 6 7 8 3 15 10 To remove back cover slide the tabs as shown ...

Page 14: ...ch 7 Recharge jack Plug the RC battery charger in here to recharge the internal battery The charger light will come on when it is connected 8 Sliding tabs to remove the back cover Slide both tabs off and take the back cover off 9 Antenna storage 10 Neck strap connecting hook 11 Left and right Trim lever for left control stick Normal Center Centers the eye pupils position 12 Forward and Reverse Tri...

Page 15: ... as if the robot starts moving on its own If the robot does start moving slowly on its own move the slider to the left of the stick or below the stick slightly until it stops The trim adjustments for the left joystick will effect the position of the eye pupils The one below the left of the stick effects the position of the pupil Typically leave in the center To remove the back cover of the transmi...

Page 16: ...eries Doubling the normal charging time is the type of over charging that is meant here and the battery getting hot When the battery level needle goes in the red the robot should be turned off because the robot could act erratic without the transmitter signal To avoid a RC battery going dead during a presentation start the program with a fully charged battery or be aware of how much charge there i...

Page 17: ...rectly to your battery The charging time is still 16 hours 110 Volt RC Transmitter Power Supply Option The 110V RC Power Supply is a power unit that plugs into a standard electrical outlet and in to the RC transmitter This allows you to have continuous power without using batteries This connects into the same connection as the battery To make the connection you need to take the back cover off the ...

Page 18: ... 151 receiver which is worn by the operator This is amplified and sent to the speaker in the operator s headset Important The operator s transmitter and receiver should be kept as far separate as possible such as on opposite sides of the operator s waist Do not attach the units together this may cause interference effects The antennas should not be wrapped around each other or around the headset w...

Page 19: ...n the power switch with a fresh alkaline 9 volt the battery light will blink on momentarily and go out This indicates that it is powering up and that the battery is good Because the light is a low battery indicator when the light is on constant this indicates the battery is too low below 7 volts Replace with a new alkaline battery Tip The operator s voice units both have metal clips that contact t...

Page 20: ...ver the robot is turned on You could turn the sensitivity down slightly but turn the adjustment as little as possible because adjusting it will affect the range Function of the LEDs TX LED This indicates that you are receiving a signal from the transmitter On some units it is a single TX light On other units it may have an A or B that it will alternate between AF LED This light indicates that audi...

Page 21: ... down until the feedback is gone Function of LEDs When turning the volume knob on with a fresh alkaline battery the red light will blink on momentarily and go out This indicates that it is powering up and that the battery has enough charge on it As labeled the light is a low battery indicator When the light is on constant this indicates that the battery is below 7 volts It then would need to be re...

Page 22: ... that the batteries are good in the operator s transmitter and in the 151 receiver Normally when you turn the 151 receiver on the low battery light should blink on and go off When turning on the power switch of the transmitter the light should blink on and go off If either of these lights stays on constant the 9 volt battery is too low and must be replaced 2 Check that the battery is in the correc...

Page 23: ...headset in 1 Low Battery LED on steady or no LED flash 1 Replace the 9 Volt battery 2 Battery posts not touching the metal clips in the operator s receiver 2 Bend out the metal clips Put foam under clips 3 Headset plug to 151 RX has a broken wire 3 Unscrew cover of plug and look for broken wire 4 Robot 151 transmitter not turned on 4 Turn on audio and power 5 Power plug to robot 151 transmitter un...

Page 24: ...sensitivity is set based on a typical voice volume and the headset microphone being about 1 inch from the operator s mouth Adjustment The adjustment is preset at the factory and should not need any adjustment If an adjustment is necessary see the Main Circuit Board diagram in the Appendix for the location of it It is labeled Moving Mouth sensitivity When this pot is adjusted clockwise this makes t...

Page 25: ...21 Chapter 3 Voice System Operator s Voice Transmitter and Receiver Diagram Operator s Voice Transmitter and Receiver 3 5mm Headphones Plug Mic Plug 3 5mm or 3 Pin mini XLR ...

Page 26: ...ssette tapes available from Robotronics with safety songs or you can customize your own tape to work with your program Troubleshooting Cassette Player No operation when you activate the tape function 1 Is the cassette fully inserted play switch pushed and the volume level up 2 Is the cassette unit receiving power If not make sure that the mode switch on the cassette player is in tape mode If it is...

Page 27: ...23 Chapter 4 Cassette Tape Player System Diagram Cassette Tape Player ...

Page 28: ...24 Chapter 4 Cassette Tape Player System Diagram ...

Page 29: ... jumper located on the siren mode select To control the oscillating speed adjust the siren frequency trim pot in the siren circuit The siren mode select is set to the common siren for your robot If the siren mode select is changed the siren frequency will very likely need to be adjusted NOTE The volume and oscillation are preset at the factory and do not need to be adjusted unless you want a diffe...

Page 30: ...uring charging for ventilation The robot is supplied with an automatic type battery charger This will recharge the battery full in 10 to 14 hours This type of charger will not overcharge the battery if left ON indefinitely Avoid leaving it charging for more than 5 days Generally remove the battery from the charger when the charger indicates a full charge Cautions Batteries are provided with a pola...

Page 31: ...y read close to 10 amperes After 5 minutes or so the meter will drop to some lower level This reading can be used as a rough guide to determine the state of charge as shown on the front panel of the charger Do not use the initial reading obtained just after starting the battery charge Some charger models will have a battery fully charged light to indicate a full charge 2 When fully charged a new b...

Page 32: ...e meter moves indicating that the battery is drawing some current Try using the battery and see if it runs your equipment If it does but not for a normal time repeat the charge and discharge two or three times The battery may recover If the battery does not recover it must be replaced 6 A fully charged Gel type battery can be left in storage for at least six months under normal conditions If the s...

Page 33: ...ne The joystick could be pushed in the on position while the connector is being checked for an intermittent connection If there is a bad connection the connector and or pins should be replaced While doing the test just explained have the robot wheels off the ground Perform the following depending on the symptoms indicated ________________________________________________________________________ Not...

Page 34: ...eed a small flat head precision screwdriver to make the adjustment The cover of the main electronics box would need to be removed to access the adjustment Take the cover of the box completely off and set outside the robot so that it cannot touch the post s of the robot battery CAUTION The robot battery posts should never contact the metal of the main electronics box or the metal of the drive base ...

Page 35: ...ave been hit out of position or the set screw is loose Try to move the head manually If you can move it back into the correct position and make sure the set screw is tight The set screw can be accessed through the shoulder access hole If you cannot manually move the head you may need to loosen the set screw re position it and then tighten the set screw The head motor is keeping the head position t...

Page 36: ...off the servo shaft or the eyelid off the ball link 2 Follow the wires from the specific servo motor with the problem The wire will run to the eye servo board If it is disconnected reconnect according to the eye servo board diagram If the servo does not work correctly wrong direction try one of the other outputs on the eye servo board One of the eyelids is at a different level than the other 1 If ...

Page 37: ... switch in the momentary position until water comes out the overflow nozzle You will fill the reservoir until water comes out You can stop sooner if you want Be sure that the water is filling in the reservoir 3 Plug the water line back in and switch the water squirter switch to the on position B How to operate your water squirter system 1 The water squirter system must have water first If not fill...

Page 38: ...e rear door or trunk If needed unlatch the top and lift the top slightly Make sure to push the top latches back afterward to keep the top secure on the lower robot The pitch shifter has two basic effects a digital pitch shifter and a delay There are many variations of these two effects When used as a pitch shifter you can vary the shift within 2 octaves Set the mode knob to Pitch shifter and then ...

Page 39: ...ot to the lower Two of the latches are located in the compartment where Patches sits The pins are to the left and right of Patches The other two are at the back of the robot To latch these you will need to reach in through the back hatch trunk 3 Connect the 37 pin connector that is a round connector and wire bundle running from the upper robot to the lower robot When connecting this rotate it unti...

Page 40: ... drive motor 4 Rotate the handles of the Link Lock Latches in the drive base counter clockwise This will release the latch from the slot of the mounting plate 5 Lift the back of the robot up and roll the drive base out from under it Installing the drive base back into the body 1 Lift the back of the robot up enough to roll the drive base under and into position 2 Line up the four aligning threads ...

Page 41: ...won t come off with soap If this causes the finish of the plastic to become dull apply ARMOR ALL brand protectant Do NOT use alcohol on windows or pupils 7 Check the Radio Control System and Voice Transceiver for broken wires controls cases etc The metal clips that are in the voice units and contact the 9 Volt battery should be bent out routinely to maintain good contact 8 Fully charge the battery...

Page 42: ...recision regular Phillips screw drivers Screwdrivers flat head and Phillips Socket and ratchet set Needle nose pliers Crimper Wire strippers Wire cutters diagonal cutters 7 16 3 8 wrenches Set of Allen wrenches Especially 3 32 and 1 8 sizes Extra 9 Volt alkaline batteries Small soldering iron and solder Small can all purpose lubricant Digital Multimeter Volts Ohms ...

Page 43: ... ball point pens etc This person can pass out stickers flyers and help give your safety presentation The following is a list of specific ways to care for the fur 1 Brush the fur regularly with a soft brush or white terry cloth towel to avoid matting over time This will help to keep it clean and looking fresh and new Be careful to be gentle excess friction may cause excess wear 2 For regular cleani...

Page 44: ...masking tape and paper to protect against over spray Method 2 Note If you use method 2 you should contact a professional painter that has had experience painting on various types of surfaces This method may not allow you to touch up the paint as easily but your painter could do the touch up when necessary Brand Sikkens Priming and Painting You could use a Scotch Brite pad 7448 or one recommended b...

Page 45: ...This will keep the glue from running Apply some of the PVC or ABS glue along the seam only on the inside of the body Check to make sure that the glue is not running through the crack on to the outside of the body Note Avoid getting the glue on your hands 5 Immediately put the fiberglass mesh on the glue and pat it down to saturate into the glue 6 Apply some more PVC or ABS glue over the fiberglass...

Page 46: ...ional maintenance that may need to be done 6 Clean the body and top as per instructions in maintenance section If robot is stored with a dirty body it may be harder to clean at a later date as stains may become permanent 7 Storing your robot with a dust cover on it will keep the robot clean and protect the body from scratches It will also keep ultra violet light from effecting the ABS plastic body...

Page 47: ...43 APPENDIX A ...

Page 48: ...lug and look for broken wire Robot 151 transmitter not turned on Turn on audio and power Power plug to robot 151 transmitter unplugged Find wire and plug it back in Operator cannot hear If you have no TX light on 151 RX mute could be out of adjustment Adjust the mute on the 151 RX to max which is fully CCW Low Battery Replace the 9 Volt battery Sensitivity Adjustment down too far Sensitivity adjus...

Page 49: ...the center Joystick potentiometer broken Send to Robotronics for repair One motor pulley set screw loose Tighten set screws Robot not driving straight Straight drive adjustment needs to be adjusted Find adjustment on the main circuit board See diagram of main board in Appendix Character Head Turning System Head is out of position but operates Loose head set screw or head was hit Re position head a...

Page 50: ...not the center position Cannot squirt no pump sound Broken wire at pump or W S switch Repair re solder broken wire Reservoir empty Fill Reservoir with filler bottle Water line is not connected to water connector Connect it Cannot squirt pump sound yes Overflow tube and squirt tube are switched at the reservoir Swap them back Overflow tube is the one that is in the top of the bottle and the tube ru...

Page 51: ...47 Appendix A Robot Functional Block Diagram Robot Functional Block Diagram ...

Page 52: ...48 APPENDIX B ROBOT PARTS IDENTIFICATION ...

Page 53: ...ector Speaker 37 Pin Connection Wire to upper robot connects here Speaker Battery Connector Serial Model Sticker 151 Voice Transmitter Water Pump Water Reservoir Water Connector Connect Filler Bottle Here Water Squirter Switch Overflow Nozzle Robot Battery Audio Booster ...

Page 54: ... Lower Robot Bottom View Front Transport Cart Eye Hooks Rear Caster Wheels Front Caster Wheels Motor Pully Set Screws Allen wrench sizes Super Motors 1 8 Standard Motors 3 32 Motor Pully Drive Belt Wheel Pully Rear Transport Cart Eye Hooks ...

Page 55: ...e Player Pitch Shifter Voice Modifier On Off Switch 331 RX Antenna 37 Pin Connector Note The Fuse Block is located inside this main electronics box Link Lock Latches Tip For best reception of the voice speaking make sure the Nady 331 Receiver antenna is fully extended Important Make sure that the robot battery strap is tight to secure the battery ...

Page 56: ...tte Audio In 101 Rx Audio In Out to Audio Amplifier Cass 3 Volt Regulator Cass 3 Volts Switching Mouth Sens Adjust Headlight Beacon Output Output 5 V to Receiver Reset Receiver Signal In White Yell Blk Signal to Eyes Servo Board Gray Yell Blk Right Drive Circuit Left Drive Circuit Patches Head movement tape player siren eyes operation voice system and mouth circuit ...

Page 57: ... super 15 AMP standard AUDIO 5 AMP Red wire Red wire Red wires 12 Volt Power wires from Main On Off Switch All Fuses are AGC type fuses Audio Fuse 0 Robot voice transmitter 151 Robot voice receiver 101 audio booster active filter cassette player siren Switching Fuse 4 Cassette player siren headlights beacon and water squirter This applies to the switching on and off of these functions Power to Pat...

Page 58: ...54 Appendix B Patches Head Patches Head Inside View Right Eyelid Servo Left Eyelid Servo Set Screw Set Screw In line connectors for each servo Mouth arm Servo Arm Eyelid Rod Eyes Left Right Servo ...

Page 59: ...id 7 Right Eyelid 8 Eyes L R Version With One 5 Pin Connection White Black Red Red 5 V Black Gray Yellow Black Brown 5 Pin Connector 1 Left Eyelid 2 Right Eyelid 3 Left Hand 4 Right Hand 5 Eyes L R 6 Left Eyelid 7 Right Eyelid 8 Eyes L R Robot Typical Connection Location of Board in Robot Patches Robot 6 7 and 8 In Patches 1 2 3 4 5 6 7 8 COPYRIGHT 1993 ROBOTRONICS 4015 1 2 COPYRIGHT 1993 ROBOTRON...

Page 60: ... Connector Servo Rod Body Latch Steering Wheel Servo Head Turning Motor Head Turning Body Latch Feedback Pot Eyes Servo Board Servo Arm Set Screw Patches Control Board 37 Pin Connector Body Latches See Patches Control Board Diagram for detail of connections on the Patches board ...

Page 61: ...ow 12V power from lower robot Signal to Eyes Servo Board Yell Gray Blk 5 Volts to Eye Servo Board Black Red Head Turn Motor Wire Signal From Lower Robot RC Receiver Blue Black Orange Mouth Trigger Purple jumper purple Blue Yellow Fuse in line 1 5 Amp Head Turn Feedback Pot wires Black red orange ...

Page 62: ...58 Notes ...

Page 63: ...59 Technical Tips ...

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