Robotronics Pluggie Robot Operating Manual

i

Pluggie Robot Operating Manual

1610 West 1600 South Springville, UT 84663

Phone: [phone] FAX: [phone]

Robotronics.com

Version 7

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ROBOTRONICS INC.

Springville, Utah 84663

www.Robotronics.com

 Robotronics Inc., 2016.
Robotronics

Pluggie Robot Operating Manual

Congratulations on your purchase of a ROBOTRONICS, Inc. robot.

Your robot has been carefully constructed of the highest quality components. Its
design is the result of years of experience building robots. You will find it an
extremely effective spokesman for your organization. It is built for ease of
operation, maintenance and repair. It is built so 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 and proper training 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 operation, maintenance, and repair. Also, if you have
technical questions relating to expanding the functions of your robot, we would be
most happy to help.

Sincerely,

ROBOTRONICS, Inc.

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Contents

Contents

Warranty Information ............................................................................................ 1

PART 1 General Operating Instructions ......................................... 3

Chapter 1 Getting Started ......................................................................3

Operating Hints ................................................................................................... 3

Setup and How to Operate the Robot .................................................................. 4

Transporting the Robot ........................................................................................ 6

PART 2 Subsystems of the Robot ..................................................... 7

Chapter 2 Radio Control System ...........................................................8

Radio Control Operating Instructions ................................................................... 8

Radio Control Transmitter (Diagram) ................................................................... 9

Radio Control Transmitter Controls ................................................................... 10

NI-MH R.C. Transmitter Battery......................................................................... 12

Charging of the NI-MH R.C. Transmitter Battery (Diagram) .............................. 12

Adapter for Charging and 110 V Power Supply ................................................. 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

VR3U System .................................................................................................... 18

Voice System Troubleshooting .......................................................................... 20

Chapter 4 MP3 Player System .............................................................22

Chapter 5 Robot Battery Systems .......................................................24

Robot Battery .................................................................................................... 24

Robot Battery Charger ...................................................................................... 25

Chapter 6 Drive Motor System ............................................................26

Chapter 7 LCD Interface ........................................................................28

Chapter 8 Eyelids and Eyes Left and Right ........................................29

Chapter 9 Optional Accessories

Water Squirter System ................................................................................... 30

Water Squirter System Diagrams .............................................................31

Pitch Shifter (Voice Modifier) ......................................................................... 32

PART 3 Assembly & Disassembly ................................................34

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Contents

Chapter 10 Assembly & Disassembly ............................................................ 34

PART 4 Maintenance .............................................................................. 35

Chapter 11 Maintenance ......................................................................35

Regular Maintenance Checklist ......................................................................... 35

Recommended Tool Kit ..................................................................................... 36

Painting of the Body .......................................................................................... 37

Repair of the Body ............................................................................................. 38

Storage ............................................................................................................. 39

Appendixes

Appendix A ..............................................................................................40

QUICK REFERENCE TROUBLESHOOTING............................................. 41

Robot Circuit Block Diagram ............................................................................. 44

Appendix B Robot Parts Identification ...............................................45

Robot Frame Front View ................................................................................... 46

Robot Frame Rear View .................................................................................... 47

Processor Board ................................................................................................ 48

Audio Mixer ................................................................................................... 49

Drive Circuit Motor Controls ............................................................................... 50

Power Distribution Board ................................................................................... 51

Robot Frame Top View ...................................................................................... 52

Cap Linear Actuator Assembly .......................................................................... 53

Base Frame – Bottom View ............................................................................... 54

Base Frame – Inside View ................................................................................. 55

Pluggie Eyes ................................................................................................... 56

Servo On Off Board ........................................................................................... 57

Notes Section* ....................................................................................................... 58

Technical Tips Section* ......................................................................................... 59

* These sections can be used to place additional notes that you would like to record, during
your use of the robot.

1

Warranty Information and Getting Help

Record the vital information from your robot here for future access

Date Received:
Customer Number:
Robot Model Number:
Robot Serial Number:
Brand of Radio Control:
Frequency of Radio Control:
Voice Frequencies
Operator Transmitter:
Operator Receiver:

Limited Warranty

All robots and accessories have a limited one year warranty, which covers all parts and labor.
This period covers the normal burn-in for electronic components. Experience has shown that
this warranty period catches most component defects and other possible flaws. If you have a
problem, we are anxious to help. Our desire is to be certain you receive a quality product and
excellent service.

Warranty work is specifically limited to correction of defects by repair or replacement of faulty
equipment or parts. The robot shall be repaired or replaced at Seller's option. Equipment
returned to the factory for repair must have pre-authorization from our service department and
must be sent freight pre-paid, and will be returned freight pre-paid by UPS ground or common
carrier. If you need parts sent by air shipment you will be responsible to pay the additional
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.

The buyer is further responsible to ensure that proper and complete training be given to those
operating the robot system as all aspects of such operation cannot be covered in a brief manual
such as this.

In no event shall ROBOTRONICS, Inc. be liable for any incidental or consequential damages in
connection with or arising from the use of this manual or any procedures contained herein.

Record The Robot’s Vital Information

If You Have a Problem

 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.

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Warranty Information and Getting Help

Important: Have the robot serial number and model number ready. This will help our

technician identify the model of robot you have. The serial and model number sticker is located
under the cap. Pop the cap off and it is on the plastic cross piece.

 If you must return a part or the robot for repair, pack it carefully and send it prepaid

according to instructions. You must obtain a return authorization number from the
service department before shipping the robot or a part to the factory.

 Parts of the robot are best sent by a carrier such as UPS, Fed. Ex. or U.S. mail,

because shipping is based on the actual weight of the package. Be sure to insure the
shipment for the correct value. A freight company such as YRC or R&L Carriers should
be used only for the complete robot, because their shipping charges are based on 100
pound minimums.

 For international shipments, you will be responsible for paying customs duties, taxes

and other fees. The shipment must be labeled on the paperwork and on the outside of
the container that it is “For Educational Purposes”. If it is a “warranty replacement”
or a “repair return” this also must be indicated both ways on the customs
documentation. Contact your customs agency on how to document the shipment
correctly to avoid unnecessary customs charges.

After The Warranty Repair and Help

Our technical staff is always available to help with your questions. Again, most problems are
easily solved. The robot is design is very modular to make removal of a part of the robot very
easy. For example the main electronics box, which houses most of the electronic circuitry, can
be removed from the frame of the robot. If you do need technical help or replacement parts,
call our Service Dept. We can usually ship them the following day you call. Please call our
service department for a return authorization number before sending a part or your robot in for
repair or modifications.

Service Department: 801-489-4466

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Operating Hints

Part 1 General Operating Instructions

CHAPTER 1 Getting Started

OPERATING TIPS AND SAFETY INFORMATION

ROBOTRONICS, Inc. robots are a unique and exciting tool in the hands of a skilled and trained
operator. The operator provides much of the excitement the robot conveys. The selection and
training of the operator should be done carefully, so as to provide a person with good judgment
and an outgoing personality. The operator is the single most important feature that the robot
has. Nevertheless, with a little practice anyone can learn to operate the robot and even those
with a shy personality can be very effective using the robot. It is important that you observe the
following safety guidelines. Include this in any operator training. Practicing with the robot and
having a program outline or script will help you have success the first few times out.

 Keep the robot indoors with the cover on when not in use. This will keep the robot clean

and the color at its best.

 Operate the robot with charged batteries in the transmitter and robot.
 Never operate the robot out of line-of-sight.
 The operator must have the radio control in their hands when the robot is on. If you

need to set the radio control down, turn the robot off first.

 Always have a trained person posted near the robot to help in crowd control, and to protect

the robot from vandalism. This person is also available to answer questions and interact
with the robot.

 Operating distance should never exceed 100 feet. When moving the robot through crowds,

the robot should be operated slowly and smoothly without any sudden changes of direction.
Walls, turns, and other obstacles are hazards to be avoided. Safe clearance should be
maintained between these obstacles and the robot.

 Never leave the robot "ON" when unattended or in direct sunlight for extended periods of

time.

 The robot is designed to be operated on hard, smooth surfaces and carpet. Avoid extra

deep shag carpet, dirt, gravel, or grass surfaces. Avoid steep inclines or large uneven
surfaces such as curbs, gutters, or uncovered electrical lines.

 When using the robot on a stage, the area just in front of the stage should be clear of

children for at least 10 feet.

 When attempting to operate the robot for the first time, do so in a large flat area without

obstacles. The operation of the controls should be done in a smooth, fluid manner. Avoid
jerking starts and stops or overreacting to the controls. When first practicing movement, it
is sometimes helpful to follow behind the robot, as robot movement will match stick
movement. (Controls respond opposite when the robot is facing the operator.)

The robot can be a highly successful tool for education and entertainment. Appropriate jokes,
stories and general conversation can be very effective. Children of all ages are strongly
attracted to the robot. They will talk to it, hug it, kiss it, and generally treat it as a good friend.
The smaller sized robots are very effective with children. They are light in weight and just the
right size to communicate with children. The most important ingredient to the use and effective
operation of the robot is common sense. The following instructions will help you get set up and
start using the robot.

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MP3 Switch

Four Top Switches

SETUP AND HOW TO OPERATE THE ROBOT

Step # 1

Read and study this manual completely before operating the robot.

Step # 2 Install and charge the batteries

To put the robot battery in the robot, tip the robot slightly to access the wing nut on the battery
door. This is located on the bottom back of the robot. After removing the wing nut, open the
door and lay the battery on the door with the battery wire harness running from left to right.
Attach the Battery connector (square black and red), to the robot connector (also square black
and red). Match red to red and black to black and connect them.

Note: The battery connector and robot connector look identical but they do connect together.

The battery door can now be closed and the wing nut put back on.
Be certain that the robot battery and radio control transmitter battery are fully charged before
operating the robot. Plug the RC battery charger into the side of the radio control and the
charging light will come on. The Pluggie battery can be charged in the robot or out. See the
Pluggie battery charging chapter.

Step # 3 Powering up

The radio control transmitter will be referred to as the “RC” in this manual. Turn the RC
"ON" first and then turn the robot "ON".

Important RC power up steps:

1. Put the four top switches in the forward
position.

2. Turn on the power switch. The display
will read switch error.

3. Move the top left switch (mp3) toward
you and the display will now come on.

Check that the RC battery voltage is 9 Volts or more. A fresh battery will show about 10 Volts
on the display. At about 8.5 Volts you will hear a buzzer indicating the battery is low and you
should charge the battery.

Tip: There is a hook on the RC that you can attach a neck strap to. You can use any RC or
camera type neck strap.

The "ON/OFF/RECHARGE" switch for the robot is located on the bottom left of the robot if you
are standing behind the robot. Push the switch forward to turn the robot on (On/Off positions
are labeled). The back position of the switch is the charging position.

Step # 4 Set the Volumes

Check that the volume of the voice and MP3 player are at the level that you want. These
volumes are located on the RC. You can also increase the master volume on the (Road Rage)
Amp inside the robot if needed. There is also a separate volume on the UHF wireless voice
receiver. To remove the cap, just grasp the bottom of the cap with your hands and give a short

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pull up. The cap will pop off. If you want to remove the body, there are instructions under the
cap for how to do this.

Step # 5 Test all the functions

Test all of the robot's functions: voice both ways, cap, eyelids, eyes, MP3, siren, and drive
movement for proper operation. The voice modifier option can be turned on and off from the
RC with the voice switch. The robot is now ready to operate. Note: The MP3 player has
sounds on it but you will need to load your music on it. See the MP3 Player section.

Step # 6 Optional Accessories Setup

For information about these, see the optional accessories section. This includes options such
as the voice modifier and water squirter. These sections will give you step by step instructions
for setup and related diagrams.

Step # 7 Powering Down

To turn off the system, turn the main switch to the “OFF” position. Finally turn off the Voice
Transmitter, Receiver and the Radio Control Transmitter.

Step # 8 Charge the batteries again

Connect the Robot 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 should be
charged if it is low.

 All of the major functions of the robot each have a section in the manual with more

details and diagrams. Refer to these for more in depth information. The Appendix
has pictures and diagrams of where various parts are in the robot. These will help
you become familiar with where the parts are located and their function.

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!

TRANSPORTING THE ROBOT

The vehicle that you use to transport the robot should have adequate shock absorption. Vans
and cars used for passengers would be the best. Transporting the robot in a trailer is not
recommended because trailers typically do not have the same level of shock absorption as a
car or van. A good rule of thumb to follow is that if the vehicle is adequate for transporting a
computer it should also be fine for the robot.

Double check that the body latches are secure. These two latch pins are found under the cap.
They push into the body latch blocks. The cap nut on the top of the cap rod should be tight
also.

Before strapping the robot to the cart, always put the robot cover on first. The robot cover
protects the body from getting scratches, keeps UV light off it, and helps the keep the cap on
during transport. Lift the robot on to the cart and place the wheels in the recess of the plastic
platform. Run the bunji cord around the robot enough times to hold it on tight.

You can leave the robot on the transport cart while the robot is in transit, to keep the robot from
rolling around.

CAUTION

If the robot is being transported in an open truck, the robot cover should be over the
robot and tied down tight around the bottom to prevent the cap from getting blown off.
If you do not have a cover you could take the cap off and put in the cab.

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Part 2 Subsystems of the Robot

Functionally, the robot is made up of the following basic subsystems:
A. Radio Control System
B. Voice System
C. MP3 Player
D. Cap Function
E. Robot Battery Systems
F. Drive Motors
G. Eyelids and Eyes Left and Right
The systems block diagram found here and in the Appendix shows how the various

subsystems and their components are interrelated.
Following are explanations of each subsystem, some operating instructions, and trouble-

shooting hints where appropriate.

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CHAPTER 2 Radio Control System

The Radio Control System consists of the control transmitter unit 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 micro-controller, which is on the main circuit
board in the vehicle. The micro-controller controls functions based on what was sent from the
radio control transmitter.

Radio Control Operating Instructions

Refer to the diagram showing the radio control transmitter for the location of controls.

RC turn on steps:

1. Put the top switches in the position away from you.

2. Turn on the power switch. The display will read switch error.

3. Pull the very top left mp3 switch and the display will now come on.

You can now turn on the main robot power switch. It is necessary for the robot to always have
an operating signal when it is on. If there is no signal you will not have full control of the robot.

The right hand joystick controls movement of the robot's drive wheels. Pushing the stick
forward will cause the robot to move forward. Pulling the stick back will cause the robot to move
backward. Moving the stick to the right or left will cause the robot to turn to the right or left
respectively. Movement is fully proportional so any variation or combination of movement is
possible. The horizontal and vertical trim tabs to the left and below the joystick are for
centering and should be typically left in the center. The only time that you would need to move
these trims is if the robot started moving slightly on its own. In this case move them slightly
until the robot stops.

The left joystick controls the eyes and the eyelids. It also controls the mp3 volume up and
down.

For a detail of other functions, see the radio control diagram on the next page. All of these
functions are labeled on the radio control itself.

A charge plug is provided on the transmitter for recharging its internal battery. The transmitter
power switch must be in the off position before charging the batteries. A charge light on the
charger will come on while charging.

There is a RC battery (NiMH) provided with all robots. There is an extra Ni-MH battery provided
with the package. These will give you about 5 hours operation each.

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1

9

12

15

16

3

5

4

6

10

11

13

14

7

8

RC Receiver located in

the robot

Drive

Drive Trim

Eyes

Power On/Off

Charge

Surprise

Siren

Cap

MP3 Player

Option

Squirter

RC

Frequency

RC Frequency and RF

Module on back of RC

Antenna Wire

Battery Voltage

8.5 V is low

IMPORTANT

Do not change the menu

settings.

The button pad, menu, and

exit buttons, are only used

for setting up RC at factory.

Volume Voice

Volume MP3

2

Left Stick

Trim

Right Stick

Trim

Radio Control Transmitter

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CAUTION

Do not change menu settings on this RC or you

may lose functionality and the settings would

need to be restored.

RC Transmitter Controls

Note: The following information on the transmitter controls includes information for a variety of

similar robots.

Important RC power up steps:

1. Put the top switches in the position away from you.

2. Turn on the power switch. The display will read switch error.

3. Pull the very top left switch and the display will now come on.

1. Telescopic Transmitter Aerial.

2. LCD Display and Transmitter Battery Voltage Meter (Expand Scale Voltmeter). Battery
Voltage is typically over 10 Volts with a fully charged battery. 8.5 Volts or less is low
and the battery should be changed. There will be an audible beep when the battery is
low.

3. Right control Stick­Up and Down – Robot drive motors, forward and reverse.
Right and Left – Robot drive motors steering. Left and right turns.

4. Forward/Reverse Trim lever for right control stick. Normal = Center. Neutrals the drive
motors. If the robot is moving slightly slide this a few clicks until robot stops moving.

5. Left and right Trim lever for right control stick. Normal = Center. Neutrals the drive
motors. If the robot is moving slightly slide this a few clicks until robot stops moving.

6. RC Frequency range. This is a 2.4 GHz system.

7. On/Off Switch.

8. Recharge jack. Plug the RC battery charger in here to recharge the internal battery.
The charge light will come on, on the charger.

9. Forward and reverse trim lever for the left control stick. Normal = Center. Unused.

10. Left and right Trim lever for left control stick. Normal = Center. Centers the head on
robots with head movement (Character in Vehicle).

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MP3 Switch

Play/Pause
Stop

Snd2
Snd1

Snd4
Snd3

Fwd. Track
Back Track

MP3 Functions

Hold the MP3 switch on to use MP3 Player

and to change volume with the left stick.

11. Left Control Stick
Left and right movement - Turning of the head left and right (Character in Vehicle)
Forward Corners- Left and right eyelids.

Top Switch Functions

12. MP3 player

13. Surprise and Siren

14. Squirter

15. Not used

16. Cap

Controls for the Integrated MP3 Player Option

The MP3 player is located in the robot and has a micro SD or MM memory card that you can
load music onto. If you have the MP3 player option then your switches will take on other
functions when the MP3 mode switch is held on. Two of the switches are for sound effects on
the SD memory card. The other two are for playing and selecting songs that you load on to the
SD card. You can also change the volume on the remote.

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Caution: Do not overcharge the batteries as this could cause permanent damage to the

transmitter batteries. (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.

Charging Jack for

the RC Battery

RC Battery NIMH

RF Module

The NiMH (Nickel Metal Hydride) RC Battery

The NI-MH RC transmitter battery will last about 5-6 hours on a full charge. Charge the battery
for about 14 hours. A charge jack is provided on the transmitter for recharging its internal
batteries. This round jack is located on the right side of the radio control. (See the radio
control diagram) The RC power switch must be in the off position when the charger is plugged
into it and must remain in the off position while charging. A light on the charger will be on,
when charging.

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 is left in the battery. If you have an extra battery
you can change batteries and keep going.

To install the NI-MH battery pack you need to take the battery cover off the RC. Disconnect the
RC battery and put the NI-MH battery in its place.

NI-MH RC Battery and Charger Specifications

NI-MH RC transmitter battery 9.6 Volts 1700mAH
NI-MH RC transmitter battery charger 11.6 Volts 130mA

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Problem/Cause

Action

Radio Control System

No robot operations

1. Robot Battery is low or bad.

1. Charge the battery overnight. If it still does not operate,
test the battery with a Voltmeter. Good level is 12 Volts.

2. RC not transmitting.

2. Check battery level on RC. Send RC back to Robotronics.

3. Processor Board is not getting power.

3. If leds are not on, check the fuse and wiring to the power
distribution board.

One or two functions on the robot not working.

1. Typically not the RC unless a switch or wire is broken.

1. Look for any broken or loose wiring inside the RC.

RC not maintaining power. Power meter will not go up.

1. Bad RC battery.

1. Try a new RC battery.

2. Charger not working.

2. Make sure your charger light is coming on.

3. If power goes on and off, could be a bad connection in RC.

3. Send your RC in for repair or replace it.

Joystick functions not working correctly.

1. Trim adjustments not in the center.

1. Put trims (sliders) in the middle.

Charging Adapter

NiMH RC Battery

Charger

Adapter for Charging an Extra NI-MH RC Transmitter Battery

If you have an extra NI-MH RC battery, you can charge this outside the RC. You may need to
do this while you are using the robot or if you need to charge both batteries at the same time.
The adapter needed to do this is in the control case or it is on your charger. It has a white
connector on one side and a connection on the other end that will go directly to your battery. If
the barrel adapter is currently on the charger, disconnect it and connect the other adapter. The
charging time is still about 14 hours.

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Operator’s Voice Transmitter, Receiver, and Headset

3.5 mm headphones
Plug

151 Receiver

Transmitter

3.5 mm

mic plug

This headset

style is available

This is the headset style that

comes with the robot.

If needed, adjust the headset

frame so that the earphone and

the frame fit comfortably and the

earphone is against your ear.

CHAPTER 3 Wireless Voice System

The Voice System consists of two separate communication links. One link transmits the
operator's voice to the robot. When you speak into the headset mic, this audio goes to a
transmitter on your belt. This audio is transmitted to a receiver in the robot. The audio signal
then goes from the receiver through a mixing circuit on the main board. It is then is fed into the
amplifier which amplifies the signal through the robot's speakers.

The second voice link transmits the audio detected by the Mic element (located in the front of
the robot) to the 151 receiver (which is worn by the operator). This is amplified and sent to the
speaker in the operator's headset. When putting the headset on, adjust the earphone so that
you can hear well and the mic so that the volume is good.

Note: The operator’s transmitter and receiver can be worn next to each other. If you want

you can use a belt pack. The 151 Receiver antenna can be put in your pocket.

Location of Voice Units

Voice Transmitter- Operator wears
Voice Receiver- On the main electronics box in the lower robot.
151 Transmitter- On the frame in the robot. The robot mic connects to it.
151 Receiver- Operator wears

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Tip: The operator’s voice units both have metal clips that contact the posts of the

9-volt battery. These must be bent out from time to time to keep this contact good.

22. Sliding door

23. 9 V Alkaline Battery

24. Front Cover

25. 3.5 mm jack

26. Off/Standby/On switch

27. Antenna

28. Volume- Input Level Control

29. Belt Clip

Frequency is listed on the back.

How to Operate the Operator’s Transmitter

1. Open the battery door.

2. Use a 9 Volt alkaline battery and insert it according to the diagram inside the battery
compartment.

3. Place the headset on your head and adjust the microphone to approximately 1 inch from
your mouth. If needed, adjust the headset frame so that the earphone and the frame fit
comfortably and the earphone is against your ear.

4. Plug the mic plug from the headset into the top of the transmitter.

5. Move slide switches to the "ON" position.

6. On the UB4 there is a Volume input level adjust on the unit.

Frequency channel- Located on the back of the transmitter.

Function of the LED

When turning on 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.

16

Tip: For best range extend the receiver antenna(s) as much as possible, not allowing it

to touch metal.

1. Power On LED Indicator

2. Diversity LED Indicators

3. AF Peak LED Indicator

4. Antennas

5. Power Switch (Leave On)

6. Frequency Label

7. Audio Output

8. DC Input Jack 12V

9. Aux. Volume Control

10. Balanced Mic Audio Output XLR

11. Squelch Control

1 2 3 4 5 8 6

11 9 7

10

How to Operate the Receiver (in Robot)

There are two adjustments on the receiver. The volume is on the back of the receiver, which
you may set to the desired volume. On the UHF UB-10 you can change the volume on your
belt transmitter on the fly. The other adjustment is the sensitivity. This is factory preset to
maximum sensitivity. This effects how sensitive the receiver is to the transmitter signal.
Typically you would never need to adjust this. The only exception would be if you get squelch
when the transmitter is off. You can deal with this by simply turning on the belt transmitter
whenever 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.

Frequency label- Located on the side of the receiver.

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 audio is going through the receiver. It will flash as you speak
into your headset mic.

17

Tip: The operator’s voice units both have metal clips that contact the posts of the 9-

Volt battery. These must be bent out from time to time to keep this contact good.

1. Off/Mute/On Switch

2. Low Battery Indicator

3. Audio Level Trim
4 Audio Jack for mic

5. Antenna

9 Volt Battery not needed in robot.

1. Battery door

2. Antenna

3. Mute control- Used if RF causes squelch. Leave Fully
counter-clockwise for best range and reception.

4. Green TX LED- Indicates signal being received.

6. Headphones jack

8. Volume On/Off

2 1 3 5 4

Frequency listed

on back

How to Operate the 151 Transmitter (in Robot)

No adjustment is needed. The switches will be preset to on at the factory. It receives its power
from the robot. No 9 Volt battery is needed.

Function of the LED

When the robot is turned on, this light flashes and then goes out. This indicates that the
transmitter is getting power.

How to Operate the 151 Receiver (Operator)

1. Remove the battery door.

2. Use a 9-Volt alkaline battery and insert it according to the diagram in the battery
compartment.

3. Plug the small round connector from the headset into the headphone jack on the top of the
151 receiver.

4. Turn the volume knob clockwise to the desired volume (if volume is too loud you will hear a
loud high-pitched feedback noise. Turn the volume down until the feedback is gone.

Frequency label- Located on the back of the receiver.
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 replaced.

18

1. Latching Battery Door

2. Battery Compartment

3. Input Volume

4. Input Jack 3.5mm

5. Audio Mute/On Turns audio on/off

6. Power On/Low Battery Led Green indicates TX is

on. Orange indicates low battery.

7. on/Off Switch Power Switch

8. Antenna Removable antenna

9. Belt Clip

1

2

3 4 5

6

7

8

9

Optional VR-3U System

How to Operate the Transmitter (in the robot)

1. Power to the transmitter is supplied by the robot battery via a 3 Volt regulator.

2. The power switch should be left on as well as the audio on switch.

3. On the UB3 there is a Volume input level adjust on the unit but typically to adjust the volume
of your hearing you will go to the VR-3U receiver which you wear on your belt.

Frequency channel- Located on the back of the transmitter.
Function of the LED

When turning on the power switch, with fresh alkaline batteries, the led light will be green. The
led will be orange if the battery is low but the battery feeding this is the robot battery.

UB-3 Transmitter (Robot to Operator)

19

Tip: The operator’s voice units both have metal clips that contact the posts of the

AA batteries. These must be bent out from time to time to keep this contact good.

How to Operate the Receiver (Operator)

1. Place the headset on your head and adjust the microphone to approximately 1 inch from
your mouth. If needed, adjust the headset frame so that the earphone and the frame fit
comfortably and the earphone is against your ear.

2. Plug the headphone plug from the headset into the top of the receiver.

3. Move the slide switch to the "ON" position.

The volume is on the top of the receiver, which you may set to the desired volume.

Frequency label- Located on the back of the receiver.
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. Green indicates you are receiving a signal. Red indicates a low battery.

VR-3U Receiver

20

!

Warnings

1. Do not unplug or plug in the DC power plug on the robot receiver with the robot
power on

2. Do not leave the voice units in direct sunlight or in a damp place for any length of time.

3. Remove batteries if voices will not be used for an extended period of time.

4. Keep voices and headset in the carrying case when not in use.

5. Generally when the robot is on, the operator's transmitter should be on. This will avoid the
receiver on the robot picking up radio frequency interference and putting out static (see
intermittent static problem of Voice System Troubleshooting).

6. Turn off the 151 receiver or remove the headset before turning off the robot. You can get a
squelch in your headset when you turn off the robot.

Troubleshooting the Voice

For any voice problem, perform the following steps first:

1. Check to see 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 correct polarity and confirm that the battery contacts are
making a solid connection to the spring clips inside the compartment. Bend them out
slightly if necessary. If the battery is making intermittent contact in the Transmitter, try a
different brand battery. Certain brand batteries are bigger than others.

3. Check all switch positions both on the operator and robot voice units. This includes the
audio and the power switches. See the Voice Unit Diagrams for details about the correct
position of these switches.

4. Check all plugs to and from the voices for proper connection.

5. Check the LED lights. When operating normally, the Receiver in the robot has a red TX
light on. The UHF UB-10 Receiver has two LEDs, A and B to indicate that a signal is being
received. The 151 Receiver has a green TX light. These lights indicate that a signal is
being sent from the respective transmitter and that the receiver is receiving this signal.

See the next page for specific problems and their solutions.

21

Problem

Cause

Solution

Voice System

Always do the following first:

1. Replace the 9 Volt batteries with new ones. USE ALKALINE!

2. Bend the battery contact out for better contact with the post of the 9 Volt battery.

3. Check power and audio switches, and lights on all voice units.

4. Check plug to and from the voices for proper connection.

5. Check if the transmit (TX) lights are coming on.

Operator cannot talk

1. Low Battery. LED on steady or no LED
flash.

1. Replace the 9 Volt battery. Is battery inserted
in correct polarity?

2. Battery posts not touching the metal clips in
the operator’s transmitter.

2. Bend out the metal clips. Put foam under clips.

3. No power to the 101 Receiver. If yes,
continue.

3. Check the in line fuse to the Receiver in robot
and audio fuse on main fuse block.

4. No TX light on the Receiver. If yes,
continue.

4. Check Sensitivity adjustment on back of
Receiver. It should be on Max. Sens.

5. Audio wires going through pitch shifter
connected wrong.

5. The wire should go from audio out of receiver
to input of pitch shifter, then from output A into
the main box and plug on to the main board.

6. Headset plug to transmitter broken.

6. Take apart and look for broken wire or solder
joint. TEST- Connect robot mic to transmitter. If
it now works, problem is in headset. Repair or
replace.

7. Still not working. Call Robotronics.

Send transmitter, receiver, and headset in.

Operator cannot hear

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
unplugged.

5. Find wire and plug it back in.

6. If you have no TX light on 151 RX mute
could be out of adjustment

6. Adjust the mute on the 151 RX to max. which is
fully CCW.

7. Robot microphone in robot is bad.

7. Order a replacement. TEST- Plug your
headset into the robot transmitter in place of the
robot microphone and test.

8. Still not working. Call Robotronics.

8. Send robot mic, transmitter, receiver, and
headset.

Voice Operates but cuts out.
Should get 50 feet without any cutouts.

1. Low Battery.

1. Replace the 9 Volt battery.

2. Sensitivity Adjustment down too far.

2. Sensitivity adjustments should be at max. on
the 151 Receiver and robot receiver.

3. Broken, loose or retracted antenna

3. Extend robot receiver antenna or replace
broken antenna.

Squelch coming from robot

1. No signal being sent to the robot

1. Turn on the operator’s transmitter.

2. Sensitivity is too sensitive.

2. Very slightly adjust sensitivity down from max.
(This will decrease your range)

Squelch in headset when turning robot
off.

1. 151 Receiver slightly too sensitive.

1. Adjust 151 RX mute slightly CW

2. 151 RX picking up interference in your area.

2. Always turn off 151 RX and remove headset
before you turn off robot.

22

Important

To use the MP3 player you will need access to software that converts audio files to the mp3
format and a card reader or slot on your computer for SD memory cards.

MP3 Switch

Play/Pause
Stop

Snd2
Snd1

Snd4
Snd3

Fwd. Track
Back Track

MP3 Functions

Hold the MP3 switch on to use MP3 Player

and to change volume with the left stick.

CHAPTER 4 MP3 Player Integrated

Integrated MP3 Player Features

 Ability to play MP3 files through the robot.
 Memory Storage Card: micro/regular SD Card.
 Four sound effects stored on the card varies with robot type.
 Space on the card to load your own music.
 Selection of songs is done with the RC.
 New feature: Adjust the volume of the music and effects from the RC.

The Integrated MP3 player will only play mp3 format files. The 128kbps compression rate is the
best choice for this player for best cueing speed. File names cannot be more then 20
characters long. Abbreviate your file names to accommodate this. When loading music it is
important that you load your songs outside the soundfx folder not in a folder, or they will not
play.

Play Music

When you first turn on the robot, the MP3 player will take a few seconds to start up before you
can operate it. To play a song, hold the MP3 mode switch and push the play switch shown on
the diagram below.

Tips

 After you move forward or back to a new track, the music will start right when you release

the switch.

 When you scroll to the last track it will stop there. If you want to go to the first track you

need to back track.

 There is an additional way to change the volume of the music/effects. It is to go to the

Road Rage audio amp and adjust the volume. When you do this, you may also need to

23

adjust the volume of the voice on the voice receiver. Do not turn the amp up too high; not
much past 1:00, because you may get some audio distortion.

 You can customize the songs and sound effects that you use for different programs by

getting additional cards and adding your own set of sound effects and music.

To Load Music on the Memory Card

Place the card in a card reader or in a SD card slot on your computer. Go into ‘My Computer’

on your desktop and find the drive that represents the card. Open this and you will see the
sound effects folder. Open the source folder where you have your MP3 music or sound effects
to transfer to the card. Drag and drop a copy of these files to the card. Make sure to put these
files separate from the sound effects folder and not in a folder. You can place the files in the
order that you want to use them. Put the memory card back in the MP3 player.

Play Sound Effects

If you want to play a sound effect, hold the MP3 mode switch while you hit the sound effect you
want (See the diagram above). You can play any of the sound effects: snd1, snd2, snd3, or
snd4 with the switch as shown. If you add sound effects or songs to be played in the place of
snd1-4 they must have the filename of snd1, snd2, snd3, snd4 to play in their place. The
sound effects files must be in the soundfx folder. The siren switch on the RC activates a siren
sound. The siren sound is a file in this folder. You can put a different sound in place of the
siren if you would like but it does need to be labeled siren.

Removing the SD Card

Turn the robot off before removing or installing the card. Remove the cap of the robot to locate
the MP3 player. Push on the memory card and it will slide out part way. Remove the card.
Now you can load music on the card. If you need more storage space, get a card with
additional capacity. If you need to add the sound effects to a new card, make a copy of the
folder with the sound effects on and place it on the new card.

Tip: Have multiple cards with different music customized for your specific presentations.

Changing the Volume

Adjust the volume knob on the top of the RC.

Order of songs playing

The songs will typically play in the order that you transfer them to the SD card.

Convert music on a CD to mp3 format

ITunes: With Itunes you will need to change the import format to mp3 format. When you insert

the CD into your computer there will be an import settings option. The other way to change to
the import setting is to go to edit preferences and the general tab. Change the import setting if
it is not on mp3. To locate the converted files on your computer go to edit preferences and the
advanced tab. This shows you the folder location where the song files are which by default is in
the itunes music folder.

If your file is in the computer, you can select the file tab and add file to library. You can now
point to where the file is on your computer and Itunes will convert the file and put it in the itunes
music folder. If the song is in itunes already, use the advanced tab and create mp3 version.
The mp3 version of the song will be put in the itunes music folder.
Windows Media Player: In Windows Media Player there is a rip tab that has options for
changing the file format and where the file will be located after being imported.

24

Caution

If the wires to the battery have been removed, observe properly polarity when re­connecting. The red wire goes to the positive terminal and black wire to the negative
terminal. Damage to electronics could result if the polarity is wrong.

CHAPTER 5 Robot Battery System

ROBOT BATTERY

The battery in the robot is a 12 Volt rechargeable sealed lead-acid AGM type battery. This type
of battery is very dependable and safe. It can be repeatedly charged and discharged.

To recharge the robot battery, plug the charger into the robot recharge jack located on the
bottom back right of the robot. You may have to tip the robot slightly to make it easier to plug
the charger plug in. Switch the main on-off-recharge switch to the recharge position which is
typically to the back of the robot. Finally connect the line cord of the charger into a 110 volt AC
outlet.

Status Indicator Led
Red Light Flashing- Charger is connected to AC
Red Light Steady- Battery is charging.
Green Light Flashing- Battery is greater than 80% charged.
Green Light Steady- Battery is charged.

Note: The battery can be left connected to maintain the battery charge over extended periods
of time.

Charging the robot battery outside the robot:

Locate the Pluggie charging cable adapter. This is a cord with a red and black rectangular
connector on one side and a connector that plugs into the charger on the other side. First
connect the round side to your robot battery charger.

Taking Care of the Robot Battery

 The number one rule for battery care is to keep the batteries fully charged at all times.
 Like all batteries, there is some discharge that occurs every day. Because of this you

should charge up the battery at least monthly during periods when the robot is not being
used.

 Also, the automatic battery charger can be left connected for extended periods of time to

keep the batteries at full.

 It is a good practice to rotate the batteries if you have two or more.
 For a battery that is outside the robot, store the battery on a wood or rubber surface not

concrete floors.

25

Trouble-shooting

The robot is not getting power:

1. Charge the battery fully. When connecting the charger, make sure that the red charging
light is coming on. If it is not, the charger could be bad or you could have a bad battery
connection (wires leading from the charging jack through the main on-off-recharge
switch and back to the battery).

2. Pull the battery connector apart and see if one of the four pins has slipped in the
connector. If it has, slide it forward and re-connect.

3. Check the fuses on the main fuse block.

The robot is operating slowly and the robot battery does not last the normal 4-5
hours:

This could be caused by a bad battery or battery charger. If the battery was stored on
less than a full charge for 2 months or more this could have damaged the battery.

Robot Battery Charger

Instructions for Proper Use and Operation (Read the Chargers Instruction Manual.)

WARNING: HAZARD OF EXPLOSIVE GAS MIXTURE

When charging, a lead acid battery gives off hydrogen gas. The AGM type is a lead acid battery
with pressure relief type vents. Although it only gives off a small percentage of the gas that a
wet lead acid battery does, the following precautions should be observed:

1. Do not position your face over the battery, at any time while making connections while
charging the battery outside the robot.

2. Do not smoke, strike a match, or cause a spark in the vicinity of the battery during
charging.

3. Charge battery in a dry, well ventilated area.

4. Do not expose the charger to rain.

5. Replace defective cords and wires immediately.

6. To reduce risk of damage to electric plug and cord, pull by plug rather than cord when
disconnecting charger.

7. Do not operate charger with damaged cord or plug-replace the plug immediately.

Personal Precautions

1. Consider having someone close enough by to come to your aid when you work near a
lead-acid battery.

2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing,
and eyes.

3. Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.

4. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters eye, immediately flood eye with running cold water for at least 10 minutes and
get medical attention immediately.

5. Never smoke or allow a spark of flame in vicinity of battery.

26

CHAPTER 6 Drive Motor System

Your robot is provided with two high quality industrial grade drive motors. Each motor controls
a drive wheel-left and right. Steering of the robot is accomplished by varying the speed and
direction of these motors. For example, when the left motor runs faster than the right, the robot
turns to the right.

Each drive motor is connected to its drive wheel via pulleys and 1/2" wide rubber timing belts.
The pulley set screws and bolts should be kept tight.

Trouble-Shooting Drive

Perform the following steps first when trouble-shooting a drive problem:

1. Do the other radio control functions operate? Do the other RC features work such
as siren and tape? If they do not, check the fuses on the robot battery and fuses on the
main fuse block in the main electronics box. Especially look at the fuse labeled 5 Volt
Regulator Processor and 5 Volt Regulator Receiver (see the fuse block detail in the
Appendix).

2. Check drive belts and motor pulley set screws. Especially if you hear the motors
activate but the robot does not move.

3. Check connections to motor controls and motor leads. These are blue and yellow
wires coming from the electronics box and going to the drive motors. There is a white
connector in line. 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:

Note: The best way to look at what the drive motors and wheels are doing is to put something

under the back of the robot to get the wheels off the ground. You will then be able to see
exactly what motor and wheel is working or not working, and in what direction.

Neither drive operates: Check the fuse on the robot battery. One of the fuses supplies power
to the drive.

One drive only does not operate either direction: Check the specific drive fuse on the fuse
block (left or right). See the fuse block detail to identify the correct fuse, or look for any blown
fuses. The fuse block is located in the main electronics box. If after replacing, the fuse blows
again, the drive motor or drive circuit could be causing the problem.

- Drive motor- If the drive motor is the problem, you would have likely heard the motor
grinding or scraping before the fuse blew. To test the motor for operation, swap the
motor wires. It is best to have the robot wheels off the ground when doing this test, in
order to see which wheel is operating. The motor wires are blue/yellow wires hanging

27



down below the electronics box. You may have to remove the robot battery, to make
the swap. If now the wheel/motor on the side in question operates and sounds fine then
the motor is good.

-Drive circuit-(motor control) If the drive motor is good, the drive circuit (motor control)
could be the cause of the fuse blowing. If this is the case, check for broken or shorted
wires and if nothing is found, contact the Robotronics' service department for
assistance.

One drive motor operates only in one direction: The motor control circuit is likely the cause
of this. Contact the Robotronics' Service Department.

The robot is not driving straight: (Veering when you drive)

Note: Be sure that both motors are operating forward and reverse at about the same speed,

and that the motor pulley set screws and drive belts are tight. If this adjustment is done when
there is something else wrong other than the adjustment, it will be difficult to get this adjustment
back after the actual problem is corrected. This adjustment would be done, for example, if the
robot veered beyond reasonable amounts when driving the robot forward, but both drive motors
are working.

If the robot veers, the reason is that one motor is going faster than the other at any given
position of the joystick. For example if at full speed, the robot veers to the right, this means that
the left motor is going faster than the right motor. To correct this you would use the
Programming Display. Remove the cap and connect it to the connection on the top of the
frame. On the menu select Set Drive. Then select forward in this case. Change the number
to a lower number and save it. Try the drive and see if a lower number is needed.

Forward Drive- Adjust the number below 50 if you want to go more left and above 50 if you
want to go more right.
Reverse Drive- Adjust the number below 50 if you want to go more left and above 50 if you
want to go more right.

These adjustments are from the robot’s point of view.
Note: You need to save the number change each time as you are testing your adjustment.

You may need to do some trial and error to get it just right. Continue the adjustment until it
drives suitably for you. It is best to use full speed during the adjusting, because this will act as
a good reference point.

The robot is moving slightly even though the drive stick is at neutral

 Move the sliders next to the drive stick until the robot neutrals out. This is called trimming

the stick. The RC display shows the changes to the trims.

 The joystick is broken or a wire has broken off the potentiometer of the joystick. Send the

RC in for repair. We need the RC receiver out of the robot also.

Contact the Robotronics' Service Department if you need any assistance or parts.

28

Menu
Random modes
Set Drive
Drive Limit Switch
Exit

Random Modes
All On - All auto features on
All Off
Eyes On – Auto Blink
Head On – robots with turn head

Set Drive
Forward- select- center is 50. Below 50 is more left.
Above 50 is more right (Range is 0-100)
Backward- select- center is 50. Below 50 is more
left. Above 50 is more right (Range is 0-100)

Drive Mode- Change to drive limit
Drive Mode Limit Switch enabled- turns drive limit on
then you must hold MP3/Mode switch to drive.
Red switches are lights/squirter holding MP3 switch
Red switches are MP3 functions not holding MP3 switch

Drive Mode Limit Switch disabled- turns drive limit off.
Red switches are MP3 functions holding MP3 switch
Red switches are lights/squirter not holding MP3 switch

Note: Lights/Squirter includes light bar, body lights, flashing lights, squirter, and
siren

CHAPTER 7 LCD Interface

The LCD Interface is a tool to make various settings on your software. You can set some
automatic modes such as auto blinking and eyes. You can also make adjustments to the drive,
for straightness of drive. Open the rear door and connect the display cable to the 9 pin
connection on the top of the frame. Note: Connect it with the robot off and then turn the robot
on. The display will start and read a number. Press the select button to go to menu. The
menu has the following modes and selections.

29

CHAPTER 8 Eyelids and Eyes Left and Right

The eyelid and eyes left and right movement is accomplished by three servo motors in the
Character or upper robot. When the switch on the radio control is activated, this signal is sent
to the radio control receiver in the robot. The micro-controller in the robot decodes this signal
and a new signal is sent to the eyes servo board. The eyes servo board is located with the
other circuit boards on the front of the robot. A diagram for this board is located in the
Appendix. The wires connected to this board take the signal to the servo itself and operate the
shaft of the servo motor to turn clockwise or counter-clockwise for opening or closing. The
rotation of the servo motor shaft is coupled to the eyelid and eyeballs with a servo arm and then
an eyelid rod.

New Auto Blink Feature

To turn the auto blink on/off: Move the red switch 13 toward you and hold for 3 seconds.
This will turn it off or on. The blinking will be random until you turn it off.

Surprise

The same switch 13 on the RC will also move both eyelids up, giving you a surprise look.

Troubleshooting Eyes

An eyelid or the eyes left and right does not operate:

1. Check the linkage from the servo motor. Look for the servo arm 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 the eyelid rod is bent, bend it back into position.

2. If the servo saver arm (white arm interconnecting the servo and the rod), is solid and

secure, the position of the eyelid can be positioned to match the other eyelid. To remove
the servo saver arm, the set screw must be removed. The eyelid level can be changed by
altering the length of the eyelid rod or changing the position of the servo saver arm on the
servo motor shaft.

There is no operation of any of the eye functions:

1. The wires that bring the signal to the eyes servo board are gray and yellow. 5 Volts power

is the black and red wires that connect to the eyes servo board. If these wires are
connected, follow them back to the board that they originate.

Wires originate on the main board. Make sure that these wires are connected well at the

servo board and main board.

30

!

CHAPTER 9 OPTIONAL ACCESSORIES

WATER SQUIRTER SYSTEM

Water squirter parts and where to find them:

Refill bottle - Comes with robot.
Water squirter nozzle - On the right arm.
Water squirter switch – On the top of the frame on new robots.
In-line fuse (5 Amp-AGC type) Located on a red wire between the switch and the main circuit

board.

Overflow nozzle - Located right beside the water squirter switch on the bottom of the robot.
Water line and connector - Located on the top of the frame. Access it by removing the cap of

the robot.
Water pump and reservoir -Located on the back of the frame. The body has to be removed to
access them.

How to fill your water squirter system:

1. Unplug the water line coming from the water squirter nozzle and plug in the filler bottle in
its place.

2. Put the main on-off-recharge switch in the recharge position. This is the fill position.

3. Hold the water squirter switch in the momentary position until water comes out the
overflow nozzle (You may stop sooner if you want). Be sure that the water is filling in
the reservoir. There will typically be a change in the motor sound when it is full.

4. Plug the water line back in and switch the water squirter switch to the "on" position.

How to operate your water squirter system:

1. The water squirter system must have water first. If not, fill your water squirter system.
Operating the water pump without water running through it for more than 10 seconds is
not good for the pump.

2. The water squirter switch on the robot, must be in the "on" position.

3. To squirt water move the squirter switch on the radio control transmitter to the on
position. This is a momentary spring loaded switch so that you can get short bursts of
squirting.

CAUTION

1. The water squirter system should not be operated without water in it.

2. ALWAYS make sure the water line is plugged in when using the water squirter or water
may damage the electronics.

The parts of the water squirter are shown on the next page.

31

Water pump

Female Water Connector

Water Reservoir

Connect Filler Bottle

Here to Fill Reservoir

Water Squirter Switch

Overflow Nozzle

Water Squirter System Parts

32

1. Check indicator – Power indicator and show
whether an effect is on or off.

2. Output Jacks. Output A is what we use.

3. DC power jack 9V center negative (blue/black)

4. Input Jack. Audio input wire from the wireless
receiver plugs in here.

5. EXP Jack. Not used.

6. Pedal Switch. Turns it on or off.

7. Thumbscrew. To release pedal.

8. D.Time Speed Knob – Delay time. Not used
in pitch shifter or harmonist mode.

9. Balance knob – This adjust the output balance
between the direct sound and the effect sound.
Typically set this on EFX for the full effect.

10. H.R. Key switch. Not used.

11. Pitch Switch. Adjusts the amount of pitch
shift.

12. Mode Switch. Selects the mode. Typically
use the pitch shifter mode.

Common Setting

Balance-clockwise

D Time Speed-Clockwise to FX

Pitch-About 2:00

Mode-pitch shifter

2

1

3

4 5 6

7

8

11 9 10

12

OPTIONAL ACCESSORIES: VOICE MODIFIER (PITCH SHIFTER)

The pitch shifter (voice modifier) can change the operator’s voice to disguise it and create a

robot character type voice. The operator’s voice signal is received like normal by the voice

receiver in the robot. The signal is then sent from the audio out of the receiver to the Input
Jack of the pitch shifter. It is modified and sent from the shifter Output A to the voice 'audio in'

on the main circuit board.

INSTRUCTIONS

33

The pedal on the pitch shifter is used to turn it on and off. Normally when you turn the robot on
the pitch shifter will turn on. When the pitch shifter is on, the power light labeled On Batt. will
be lit. The shifter will take a few seconds to power up. To turn it off, push the pedal again. If
the pitch shifter is not turned on, your unmodified voice will come through.

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 vary the pitch knob until you get the
sound of voice that you want. You can get a similar effect with the harmonist position but the
pitch shifter gives you the best sound. These are the most common modes used because
these modes give you the ability to adjust the shift of your voice to exactly what you want
whether up or down. About 2:00 on the pitch knob gives you a good voice but different
operators may want to vary this.

The shifter gets power from the robot battery; no internal battery is needed. If the cover of the
main electronics box ever needs to be removed, do not allow the shifter power wire plug, to
contact the metal box. The metal box surface has a ground connection. The fuse related to
the shifter is the audio fuse located on the fuse block.

Above is a typical setting for the robot voice. This will give you a shifted cartoon character or
robot type voice. If you do not want any change to your voice you can turn the balance knob all
the way down.

Boss Pitch Shifter

If you have the Boss pitch shifter, the settings are the same except that the Balance and the D.
Time Speed are combined into one knob.

How to turn the pitch shifter off

When you turn on the robot the shifter comes on. If you do not want it on, find the switch on the
RC transmitter labeled voice. This will allow you to turn it on and off. Hit the switch to turn it off
and hit again to turn it back on. When the pitch shifter is on, the power light will be lit but you
will not be able to see this because it is down in the robot. The shifter will take a few seconds to
power up.

34

PART 3

CHAPTER 10 Assembly & Disassembly

Removing the cap

1. Put your hands on the bottom rim of the cap, a hand on each side. Give a quick pull up and
the cap will pop off the cap rod. It is not necessary to remove any of the nylon bolts to
remove the cap. There is a sticker on the black crosspiece listing step by step removal of
the body. These steps are listed below.

Removing the body from the frame

1. Remove the cap of the robot as described above.

2. Unscrew the cap nut which is on the cap rod.

3. Disconnect the any and all wire and connectors connecting into the top of the frame. These
include:

 16 pin round connector (this includes eye servo and eye lights wires).
 microphone wire with plug.
 water squirter hose (optional feature).

4. Unlatch the body latches that attach the body to the frame. These are located to the left
and right just above the frame. Pull the latch pins inward to unlatch.

5. It is easiest to pull the body off by putting your hands down along the bottom edge of the
body at the seams. Pull out slightly and then up. As you lift up make sure that the wires no
wires are still connected and that the wires do not catch on the body as you pull it off.

Attaching the body to the frame
Reverse the above steps.

Removing the eye box from the body

1. Remove the three nylon bolts just below the eye holes in the body.

2. As the last one is removed, you will feel the eye box starting to come down. Hold the eye
box with one hand and lower it down to the floor. Lift the body up to get the eye box off the
floor.

Install the eye box in the reverse order.

35

PART 4

CHAPTER 11 Maintenance

Regular Maintenance Checklist

Periodically the robot should receive a thorough inspection.

1. Examine the exterior of the robot and make repairs as necessary. See the robot

body repair instructions if needed.

2. Remove the body. Check all bolts and nuts for tightness.

3. Examine electrical wiring and connectors for looseness and wear.

4. Clean and lubricate mechanical parts of the robot such as the front wheel

casters as needed. Inspect the drive belt and pulley system making sure that
the motor pulley set screws are tight. You can use belt dressing on the drive
belts if they are dry or squeaky.

5. Clean the cassette tape system according to instructions in the Cassette Tape

Player pages.

6. Wash the robot body with mild soap and water and a soft cloth and reattach the

body. (Rubbing alcohol may be used on stains that 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 the eyes.

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 and test all robot system functions. This must be done

on a daily basis when the robot is in constant use. Remember, the robot battery
should be brought to a full charge after each use of the robot so that it always
has a full charge on it.

To prolong the life of your robot system, always store in a safe place away from light, dust,

moisture, and excessive heat. To keep dust and light away from the robot, a

robot cover should be used. The robot and Radio Control Transmitter batteries

should be stored fully charged. Transport and store the robot standing up. (Never upside
down!)

For a list of recommended tools for a tool kit, see the next page. Ask us about the Robot
Maintenance tool kit that is available.

36

Recommended Tool Kit

Fuses- 1, 3, 5, 15, 20, 30 Amp (AGC Type)
4" cable ties
#53 Miniature bayonet bulbs (automotive panel type)
Precision 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)

Software in the robot

The robot this manual is for makes use of open source firmware libraries for Arduino. If you
would like copies of these libraries email us your contact information and we will arrange for you
to get copies.

37

PAINTING OF THE ROBOT BODY

The following information is only suggestions of painting methods. Contact a professional for
assistance. The paint used is typically on a sticker under the cap.

Preparing the surface:
The robot body is an ABS plastic and should be cleaned before painting to remove oils and

dirt. This is especially true if the surface has had a protectorant such as Armor-All put on it.
If the body has not had a protectorant or other silicone product used on it, you could clean the
area with isopropyl alcohol to prepare it. It helps to smooth the rough edges of the scrapes or
scratches before painting with a 600 grit sandpaper. You can lightly sand the area to paint with
the 600 grit sandpaper or a Scotch-Brite 7448 pad for better adhesion of the paint.

Painting the surface:
Method 1

Enamel spray paints such as Krylon Interior/Exterior enamel could be used. This can be
touched up easy if the paint ever got a scuff or scrape but is typically just for painting trim,
bumpers, gauge plates etc. Carefully cover parts that are not to be painted with 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. These are automotive type paints and typically include a
primer and base coat. For a glossy look you can use a glossy base coat or a clear coat.

Brand-Valspar

Primer: Check with painter.
Paint: Valspar LVB polyurethane enamel
Clearcoat: Cromax Premier LE

Brand- Dupont

Primer: Acrylic Urethane Flexible Primer Surfacer. One brand: mar-hyde (Talsol Corporation).
Other brand: 5 Star Auto body Products Maximum 2K (5404) Use with activator (5406).
For additional flexibility: Can use Dupont Plas-stick Flex Additive (2350S) with the primer.
Paint: Acrylic Enamel. Dupont ChromaBase Basecoat.

Brand- Sikkens

Primer: Plastoflex primer by Sikkens
Paint: Autocryl by Sikkens (two-part acrylic urethane enamel)

The information listed includes suggestions and general information. This material is designed
for application only by trained professional painters using proper equipment.
If you have any questions, call our service department at 801-489-4466.

38

REPAIR OF THE ROBOT BODY

Materials
Super glue
ABS or PVC clear medium bodied glue
Fiberglass mesh
Rubber gloves

1. Hold the crack together tightly so that the glue you put on the inside of the body does not
run through the crack on to the outside of the body. This would etch into the plastic.

2. If there are pieces of plastic reinforcement across the seam or crack that are unglued, PVC
or ABS glue can be used between the reinforcement piece and the body. A clamp could be
used to hold the plastic tightly together while drying.

3. Cut a piece of fiberglass mesh to cover the crack.

4. Position the body, so that the seam or crack is horizontal to the table. 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 mesh to saturate it some more.

7. It will dry to the touch in about 30 minutes. Allow 24 hours for complete drying.

8. For cracks that need more strength, glue a piece of ABS plastic across the crack with PVC
glue.

General Precautions:
Use in a well ventilated area.
Use gloves to avoid getting glue on your hands.
Avoid getting the fiberglass on your skin or clothing. The fiberglass will not hurt you, but

could cause skin irritation.

For further precautions, read the super glue, PVC, and ABS container labels.

39

!

Storing your robot for any length of time.

STORAGE

1.

2. Charge the RC battery as per instructions.

3. Remove batteries from operator’s transmitter and receiver.

4. The RC Transmitter and voice pieces should always be stored in the carrying case; this

5. Inspect robot for loose bolts or any additional maintenance that may need to be done.

6. Clean the body and top as per instructions in maintenance section. (If robot is stored

7. Storing your robot with a dust cover on it will keep the robot clean and protect the body

8. The robot and batteries should be stored in a dry place between 55-75 degrees F.

9. After storing the robot for any length of time always test the robot well in advance of any

Charge the robot battery. (Storing the battery for any length of time without

being fully charged will permanently damage the battery.)

will extend the life and help insure proper operation.

with a dirty body it may be harder to clean at a later date, as stains may become
permanent.)

from scratches. It will also keep ultra-violet light from affecting the ABS plastic body.

Storing the robot in a safe place will prevent scratches and extend the life.

scheduled activity as it is impossible to anticipate problems. This will ensure time to
correct the problem.

40

APPENDIX A

41

Problem

Cause

Solution

General

No functions operate

1. RC battery not charged

1. Fully charge until the needle is up.

2. Broken wire from the receiver to main board

2. Resolder or repair wire.

3. Fuse blown.

3. Check 5 Volt Reg. and processor fuse.

4. Main board in robot not getting power

4. Check pins of battery and robot connector.
Check on/off switch wires. Check ground wires.

5. Radio Control transmitter or Receiver
Crystal broken.

5. Replace crystals. Send RC and Receiver in to
determine if it is a crystal.

Voice System

Always do the following first:

6. Replace the 9 Volt batteries with new ones. USE ALKALINE!

7. Bend the battery contact out for better contact with the post of the 9 Volt battery.

8. Check power and audio switches, and lights on all voice units.

9. Check plug to and from the voices for proper connection.

10. Check if the transmit (TX) lights are coming on.

Operator cannot talk

Low Battery

Replace the 9 Volt battery.

No power to the 101 Receiver.

Check the in line fuse to the Receiver in robot and
audio fuse on main electronics box.

Battery posts not touching the metal clips in
the operator’s transmitter.

Bend out the metal clips.
Headset plug to transmitter broken.

Take apart and look for broken wire or solder joint.

Operator cannot hear

Low Battery

Replace the 9 Volt battery.

Battery posts not touching the metal clips in
the operator’s receiver

Bend out the metal clips.
Headset plug to 151 RX has a broken wire.

Unscrew cover of plug 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.

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.

Voice Operates but cuts out.
Should get 50 feet without any cutouts.

Low Battery

Replace the 9 Volt battery

Sensitivity Adjustment down too far.

Sensitivity adjustments should be at max. On the
151 Receiver and robot receiver.

Broken, loose or retracted antenna

Extend robot receiver antenna or replace broken
antenna.

Squelch coming from robot
No signal being sent to the robot

Turn on the operator’s transmitter.

Sensitivity is too sensitive.

Very slightly adjust sensitivity down from max.
(This will decrease your range)

Squelch in headset when turning robot
off.

151 Receiver slightly too sensitive.

Adjust 151 RX mute slightly CW

151 RX picking up interference in your area.

Always turn off 151 RX the robot.

Siren

No siren

Siren file on MP3 Player card is gone.

Restore file to SD card or put in your own audio
file.

Siren volume not loud enough
Booster problem if MP3 and voice vol. also are
not loud enough

Replace or have booster repaired.
MP3 volume too low.

Adjust MP3 Volume on the RC

Appendix A: Quick Reference Troubleshooting Chart

Quick Reference Troubleshooting

More detailed troubleshooting by system is included with each subsystem. For additional help or parts call
our service dept. at 801-489-4466.

42

Problem

Cause

Solution

Robot Battery System

No functions will operate.
Check wires and connector from battery to the

robot.

Push battery connector pins in until it clicks in
place. Pin could have slipped out of position.

Battery is very low or bad.

Charge battery or replace if it will not charge.
Also test charger.

Battery will not take a full charge.
Needle on charger will not move.

Battery has not been kept fully charged

Charge and discharge repeatedly. Replace
battery if it does not start charging.

Drive Motors

Neither drive operates only.
To correctly evaluate drive problems,
look at wheels off the ground.

Both drive fuses blown.

Replace drive fuses on fuse block.

Radio control drive section problem.
Contact Robtronics for help.

One drive only does not operate.
Determine first if it is the drive motor or

drive circuit. To do this swap the wires
that go to the motors at white
connector. Same motor still not
working then motor is bad. Problem
switches to other motor, then problem
is in main box possibly the drive circuit
itself.

Drive motor pulley loose.

Tighten motor pulley set screws.

Broken connection at motor connector.

Check blue/yellow wires and in line motor
connector at motor

Drive circuit not getting power.

Check drive motor fuses on fuse block (blue
wires). Check wires coming from fuse block to
motor circuit on the main board. Broken solder
joint?

Drive motor damaged.

Repair or replace motor.

Drive Circuit on main board problem.

Send main electronics box back to Service Dept.

Drive motors moving on their own even
when the stick is in the center.

Drive trim sliders not in center.

Move drive stick sliders to center or position to
neutral the robot.

Joystick potentiometer broken.

Send to Robotronics for repair.

Robot not driving straight.
One motor pulley set screw loose.

Tighten set screws.

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 and tighten set screw. Better to
do this with the robot on.

Head motor is keeping head in not
centered position

Head turning pot or pot shaft slipped

Re-center head by adjusting head turning
feedback pot- blue pot below motor. Then tighten
the set screws on the metal tube. See procedure
in head section.

Head motor is not operating
Character board is not getting power

Check fuse on main fuse block.

Broken wire.

Check power (red/black) and motor wire
(blue/yellow).

Eyelids and Eyes Left and Right

An eyelid or eyes L/R does not operate

Rod linkage came off.

Get to eyelid rods and ball links and re-attach.

Servo wire broken or wire came out of eye
servo board

Trace wires from servo motor of the eyelid or eyes
and follow this wire to the eye servo board to find
problem.

One of the eyelids is at a different level

Eyelid rod bent or eyelid out of adjustment

Straighten bent rod or change eyelid position by
removing the servo arm. Then shorten or
lengthen the rod by twisting the servo arm. You
can also change the position of the servo arm on
the servo shaft.

No operation of any eye functions.

Connection at eye servo board has come off.

Vehicle- located on underside of upper robot.
Robots with Character- located in character.

Wire(s) bringing 5 Volts and signal to servo
board are not making a connection. Broken
out of 37 pin connector.

Vehicles- locate the wires
(red/black/gray/yellow/black) going from the 37 pin
up to the eye servo board. Repair broken wiring.
Robots with Character- Check gray/yellow/black
and red black to eye servo board.

No 5 Volts going to eye servo board.

Find broken wire on red/black or check fuse for
eye servos on fuse block.

Appendix A: Quick Reference Troubleshooting Chart

More detailed troubleshooting by system is included with each subsystem. For additional help or parts call
our service dept. at 801-489-4466.

43

Problem

Cause

Solution

Water Squirter

Cannot fill reservoir
In-line fuse blown.

Replace the 5 Amp fuse which is in-line on the
wire. Follow wire from water squirter switch.

Broken wire at water squirter switch or coming
from main box

Repair break.

Cannot squirt: no pump sound.
Water squirter switch is not in on position.

On position is not the center position.

Broken wire at pump or W.S. switch.

Repair/re-solder broken wire.

Cannot squirt: pump sound yes

Reservoir empty

Fill Reservoir with filler bottle.

Water line is not connected to water connector

Connect it.

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 runs to an
outlet on the bottom of the frame.

Voice Modifier

Voice not being modified

Modifier not turned on.

Push pedal on modifier. Light should come on.

Audio wires not plugged in correctly

Jumper wire goes from Nady Receiver to Input of
Modifier. Wire in Output A of modifier goes to the
main board.

Appendix A: Quick Reference Troubleshooting Chart

More detailed troubleshooting by system is included with each subsystem. For additional help or parts call
our service dept. at 801-489-4466.

44

Appendix A: Robot Functional Block Diagram

Robot Block Diagram

45

APPENDIX B

ROBOT PARTS IDENTIFICATION

46

Audio Mixer

Processor Board

Power Dist. Board

On Off Servo Board

Radio Control

Receiver

Cap Actuator Relay

Motor Control

Robot Frame Front View

47

Body Latch

On/Off/Recharge

Switch

Cap Linear Actuator

Cap Rod

Wireless Voice UHF

and Antennas

151 Voice Transmitter

Water Reservoir

Water Pump

Body Latch

Audio Booster

Overflow tube

Robot Frame – Rear View

48

Green

Lcd

Interface

Blk/Red

From Audio

Mixer 5V

5 V

Power

NC NC Blue Purple Grey White Black Red Brown Green NC
5 Pin 3 Pin 3 Pin
Receiver Channel Wires- Signal from Receiver

Blue/Green

Audio Mixer

Gray

On Off

White

Lcd

RC Receiver

Channels

1 Green
2 Brown
3 Red
4 Black
5 White
6 Gray
7 Purple
8 Blue

PWM

Data Led

Power

Led

Processor Board

49

Audio Mixer Board

1 I2C from Processor Board- orange/yell.
2 I2C from Processor/5Volts- Red/Blk/Gr/Blue
3 I2C
4 I2C Data to MP3 Player-Green/Blue
5 Audio from MP3 Player-Gray/Blk/White
6 Voice Audio from VR3U Receiver
7 Left Channel Audio to Amp-Blk/White
8 Right Channel Audio to Amp- Blk/White
9 Power to Board 12 V
10 jumper- Mouth triggering select
11 jumper- Music channel pass through
select
12 Level adjust for Aux. audio input to the
right of this adjustment.

11

5

6

7

8

1 2 3

4

9

10

12

1

Audio Mixer

50

Signal from
Processor

Blue
Green
Black
Red

Motor Wires

Blue/Yellow

Fuses

1 Amp
20 Amp
20 Amp

Power

Led

Data

Led

Drive Circuit

51

Main Power 12 V

from Battery

Fuse Audio

Power

5 Amp

LCD Inter.

Pwr

MP3

Pwr

RC

Receiver

151 TX

12V

Servo Board

Pwr 12V

Cap Actuator

Relay Board

Pwr 12V

Servo On Off

Pwr

Eye Servos

Cap Actuator

Squirter

Pitch Shifter

9V

Audio Mixer

12V

Amp Power

12V

UHF Receiver

12 V

VR3U

Pwr 3V

Pwr to

Processor

Bd. 9V

Power Distribution

52

Body Latch

Female Water

Connector

Filler Bottle Plugs in

Here to Refill

Microphone Jack

16 Pin Connector

Eye Servos

Body Latch

MP3 Player

with SD card

Squirt for Squirting

Water.

Fill For Filling Water

Reservoir.

On some robots the

VR3U transmitter is

located next to the

MP3 Player. The mic

connects directly to it.

LCD Interface Display

Connector

Robot Frame – Top View

53

Cap Linear Actuator

Cap Rod Linkage

The actuator is also attached at
bottom of actuator on a rod with two
collars.

Cap Linear Actuator

54

Water Squirter Overflow

Nozzle

Left Drive Wheel

Rear Caster Wheel

Water Pump Switch

On/Off/Refill

Battery Door

Wing Nut

Left Motor Pulley

Left Drive Motor

Pulley Set Screw

Left Drive Belt

Speakers

Power Switch
Forward – On
Center – Off
Back - Charge

Right Drive Motor
Pulley Set Screw

Right Motor Pulley

Right Drive Belt

Right Drive Wheel

Battery Recharge

Plug

Battery Access Door
Front Wheel Caster

Base Frame – Bottom View

55

Water Squirter Overflow

Nozzle

Right Drive Wheel

Water Pump Switch

On/Off/Refill

Left Drive Motor

Right Drive Belt

Speakers

Power Switch
Forward – On
Center – Off
Back - Charge

Right Drive Motor

Left Drive Belt

Left Drive Wheel

Battery Recharge

Plug

Battery Access Door

Base Frame – Inside View

56

Top View of Eyes Inside Robot

Right Eyelid

Servo

Left Eyelid

Servo

Set Screw

Set Screw

Eyelid Rod

Eyelid Rod

Eyes Left/Right Servo

16 Pin Connector

Ball Link

Ball Link

Pluggie Eyes

57

White Red Blk

S1
S2 Eyes (Option)
S3 Right Lid
S4 Left Lid)
S5
S6

Serial Data from

Processor Board

Gray Wire

Data Led

12 V Power In
Red/Black
Fuse 10 Amp

Reset

Cap Actuator

Black/Yellow J23

Squirter Pump

Black/Blue J19

Red/Black J17

Servo On Off Board

58

Notes

59

Technical Tips