Kongsberg HiPAP 502 High Precision Acoustic Positioning System Instruction manual

Sonar room requirements, page 17

Hull unit location, page 19

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

About installation drawings

The installation shipyard must provide all necessary design and installation drawings, as well as the relevant work standards and mounting procedures.

Note

If required, all documents provided by the shipyard for the physical installation of the HiPAP Hull unit system must be approved by the vessel’s national registry and corresponding maritime authority and/or classification society. Such approval must be obtained before the installation can begin. The shipowner and shipyard doing the installation are responsible for obtaining and paying for such approval.

Kongsberg Maritime offers free advice for installation planning. Proposed arrangements may be sent for commentary or suggestions. The following drawings should be submitted should assistance be requested:

• General arrangement

• Body plan and drawings of the relevant compartment

• Lines plan

Tools, equipment and consumables required for HiPAP Hull unit installation

In order to do the HiPAP Hull unit installation, all necessary tools and equipment for mechanical work, cabinet installation and electrical wiring must be available.

It is not practical to provide a detailed list of all necessary tools and equipment. You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electronic and electromechanical tasks. This includes different screwdriver types, pliers, spanners, a cable stripper, a soldering iron, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

However, you must make sure that the following specialized tools are available.

• All necessary tools and consumables required for welding

• All necessary tools and consumables required for physical installation of units, cabinets and racks

• All necessary tools and consumables required for electrical installations

• A crane capable of lifting the individual HiPAP Hull unit cabinet

• A crane capable of lifting the entire hull unit

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Preparations

Note

If you need specific consumables, or if special tools and/or test instruments are required, these are identified in the relevant procedure(s).

Torque

All the nuts and bolts used in the system must be tightened to their recommended torques to prevent leaks or damage to the threads. Follow the recommended tightening torques for the various sizes.

• M6 — 7 Nm

• M8 — 17 Nm

• M10 — 33 Nm

• M12 — 57 Nm

• M16 — 140 Nm

• M20 — 273 Nm

• M24 — 472 Nm

• M27 — 682 Nm

• M39 — 990 Nm

Sonar room requirements

About the sonar room

The sonar room is the compartment in which the Transceiver Unit and the Hull Unit are installed.

It is strongly recommended to use a dedicated compartment to house these units. They must also be installed relatively close to each other due to the limited length of the cables.

Note

It is strongly recommended to use a dedicated compartment to house these units. They must also be installed relatively close to each other due to the limited length of the cables.

The sonar room must be large enough to house all the system units. The room must provide enough space to allow efficient maintenance. You must be able to keep all the cabinet doors fully open without undue restriction to your movements.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

The sonar room must be easily accessible using a suitable hatch or a door.

Lights must be permanently installed in the sonar room.

The sonar room must be equipped with a telephone, an intercom system, or any other means of oral communication between the sonar room and the bridge and/or control room(s).

Ventilation requirements

The sonar room must be connected to the vessel's ventilation system to ensure a supply of cooling air.

We recommended that you keep the ambient temperature between +5 and +40°C, and the relative humidity less than 80%. The Mean Time Between Failure (MTBF) will decrease if these limits are not exceeded.

If a ventilation system is not available, install two 3” pipes from the sonar room to a suitable fresh air location on deck. The fresh air should enter the room as close to the floor as possible, and should be extracted from as high as possible. Funnels must be located below the pipes to collect any condensation which may form. On the main deck, the best ventilation is provided when the outlet pipe is at least four meters higher than the inlet pipe. To keep out sea water, rain and spray, the ventilation pipes must be fitted with goosenecks or an equivalent design.

Note

If the vessel is likely to operate in tropical conditions, a suitable air conditioning system must be installed. The air conditioning system must be able to provide an ambient temperature that does not exceed the maximum operating temperatures of the HiPAP

Hull unit units that are installed in the room.

Requirements for bilge pump and decking

If the sonar room is located below the water line, it must be connected to the vessel's bilge pump system.

Bilge pump requirement

If it is not possible to connect the sonar room to the vessel's bilge pump system, a separate bilge pump for the compartment must be installed.

Install and activate bilge high level sensors to provide an early warning of abnormal accumulation of water. Position the sensors as low as possible along the centre area of the compartment, and/or in other locations where the water will gravitate to first. Inspect the bilge sensors periodically.

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Preparations

Decking requirement

Once the installation has been completed, the sonar room must be suitably decked without restricting access to the equipment and the cables.

Hull unit location

All hydroacoustic instruments are subjected to noise. It is important that the location of the hull unit is chosen to minimize noise.

Important

Selecting the optimum location for the hull unit is of vital importance for the overall system performance.

All external noise sources (sea noise, machinery noise, air bubbles etc), and the individual performance of the ship, must be taken into consideration.

The hull unit location must be selected by a skilled engineer with experience in positioning system theory and hull unit installation. The supplier will assist if required.

The compartment, within which the hull unit is to be mounted, must be accessible under all conditions. Take into consideration the following:

• The access door / hatch should be large enough to allow installation and removal of the hull unit without the requirement to disassemble it.

• The hull unit will pass through a hole of 800 mm diameter, provided there are no obstructions either side of the hole.

• The compartment should also be connected to the ship’s ventilation system. In tropical regions an air dehumidifier is recommended to reduce the likelihood of problems and corrosion due to condensation.

• The compartment should also be supported by a central or separate bilge pump.

The hull unit should be located within 1/6 to 1/3 of the ship’s length between perpendiculars (LBP), measured from the fore perpendicular (FP). Deviations from this specification should not be made without consulting the supplier. In all cases, it is imperative that the transducer array has a free view under the keel when it is in its operational position.

The location must be as close to the keel as possible. The vertical distance from the lower edge of the keel to the top of the mounting flange must be discussed with the supplier.

• The assistance of a dockyard crane will be required to lower the hull unit into the vessel.

• Heater elements of approximately 1000 watts should be installed close to the bottom of the hull unit to prevent the unit icing up in cold weather.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

• If there is any chance of damage caused by welding or other work during the installation or a maintenance period, the hull unit must be protected with heat resistant material.

• The installation must be approved by an appropriate classification society.

• When the vessel has been launched, the air must be released from the transducer dock through the air vent cock.

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Installing the HiPAP Hull unit system hardware units

Topics

Installing the mounting flange, page 22

Accuracy and tolerance requirements, page 23

Installing the gate valve, page 24

Installing the hull unit on the gate valve, page 25

Installing the hoist motor, page 27

Installing the hull unit controller, page 28

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Installing the mounting flange

The mounting flange must be mounted so that it remains vertical during normal operating conditions.

Prerequisites

This task must take place in dry dock. The shipyard must provide all necessary tools and manpower.

The mounting flange is heavy. Always use appropriate lifting equipment to minimize risk of personnel injury or equipment damages. Only certified equipment must be used.

The top mating surface of the mounting flange must be protected with a wooden cover at all times until the gate valve is installed.

Note

The quality of the welding is critical to the safety of the vessel. Welding must only be done by a certified welder. Always wear the personal protective equipment. Observe and obey the relevant safety instructions.

The final installation work must be approved by the vessel’s national registry, the corresponding maritime authority and/or classification society.

Procedure

1 Define the physical location of the mounting flange.

This location must be carefully selected. The decision must be based on the general principles outlined in chapter Preparations and all relevant knowledge about the vessel construction.

Note

All information related to practical and theoretical noise patterns along the hull must be taken into consideration.

2 Note the orientation of the centre line of the mounting flange with regards to the mounting bolts.

3 Cut out a hole in the vessel’s hull with a diameter large enough to accommodate the mounting flange.

The exact size of the hole must be determined by the installation shipyard.

4 Orientate the mounting flange correctly, and weld it into position.

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Installing the HiPAP Hull unit system hardware units

Important

To obtain optimal HiPAP Hull unit system performance, the total height of the mounting flange must be as close as possible to its stated minimum height.

The top flange must be parallel to the water line in both the fore-and-aft and athwartship directions.

5 Check the upper surface of the mounting flange to ensure that it is level, undamaged and clean.

6 Cover the upper surface of the mounting flange with a wooden plate to protect it

7 Brace the mounting flange to the hull plating and the surrounding hull frames by adding several strengthening plates.

The plates must be at least 1.5 times as thick as the surrounding shell plating. The final dimensions of the doubling plate must be defined in the approved installation drawings supplied by the shipyard.

8 Make sure that the hull plating surrounding the trunk is even and smooth without protruding objects that can cause noise.

Objects protruding from the hull will generate turbulence and flow noise. This will reduce the overall performance of your system.

9 If necessary, grind and polish all surfaces.

10 As soon as all installation, welding and grinding has been done, prime or paint the trunk and the surrounding area using a high quality protective coating.

You must also apply the protective coating to the inside of the installation trunk.

Accuracy and tolerance requirements

It is very important for the system accuracy that the angular orientation of the hull unit is as accurate as possible.

This implies that the welding of the mounting flange into the hull must be completed with the tolerances according to the following three offset angles:

1 Roll angle : The upper surface of the mounting flange must be horizontal in the athwart ships direction when the ship is floating at its normal trim.

Tolerance: ±1°

2 Pitch angle : The upper surface of the mounting flange must be horizontal in the fore-and-aft direction when the ship is floating at its normal trim.

Tolerance: ±1°

3 Azimuth angle : No angular requirements.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Installing the gate valve

The gate valve must be mounted so that its top mating surface is in parallel with the sea surface during normal operating conditions. The transducer dock on top of the gate valve must remain vertical during the same conditions.

Prerequisites

This task must take place in dry dock. The shipyard must provide all necessary tools and manpower. The following specific items are required for this task:

• Silicone grease

• Anti-seize lubricant

• Torque wrench

• Lifting arrangement

• O-ring

• Mounting hardware

Note

The gate valve is heavy. Appropriate lifting equipment (lifting tackle, portable crane or ship’s crane) is required. Always use appropriate lifting equipment to minimize risk of personnel injury or equipment damages. Only certified equipment must be used.

It is assumed that the mounting flange has been installed correctly.

Context

Only the basic steps of the task are offered. Additional procedures with more information and/or details must be provided by the installation shipyard to fit the vessel properties.

The top mating surface of the gate valve must be protected with a wooden cover at all times until the transducer dock is installed. It is very important that this surface is clean and undamaged, because it must be watertight after the transducer dock has been installed.

Caution

The sealing capability of the gate valve is dependent on clean and scratch free surfaces.

It is important that the valve is protected against welding spatter, grit etc.

Procedure

1 Attach the necessary tackles to the gate valve, and make sure that the unit is lifted with the correct side up.

The gate valve will work in any position, but we recommend that it is mounted with its identification tags and classification markings facing up. You must also consider the access to the end switches, and (if relevant) the hydraulic hose connections.

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Installing the HiPAP Hull unit system hardware units

2 Lower the gate valve down into the hull unit compartment, but stop when the unit is a few centimetres above the mounting flange.

Note

Do not damage the mating surfaces on the valve, the end switches, or (if relevant) the hydraulic actuator.

3 Verify that the mating surface on the valve is clean and undamaged.

4 Prepare the mounting flange.

a Remove the protective cover from the mating surface on the mounting flange.

b Verify that the mating surface on the mounting flange is clean and undamaged.

c Wipe a thin film of silicone grease on the O-ring and place it in the groove on the mounting flange.

5 Attach the nuts and washers while the gate valve is still suspended.

6 Lubricate the threads with a high grade commercial anti-seize lubricant.

7 Lower the valve carefully onto the mounting flange while tightening the nuts.

8 Verify that the valve is orientated and aligned correctly.

9 Disconnect and remove the tackles from the gate valve.

10 Tighten the nuts to the recommended torque.

Installing the HiPAP Hull unit system hardware units

Installing the hull unit on the gate valve

The upper parts of the hull unit include the mechanical gantry, the hoist motor, the hoisting spindle and the junction box. The transducer shaft is supported by the gantry, and penetrates the mounting flange. The complete assembly is mounted on top of the mounting flange.

Prerequisites

The shipyard must provide all necessary tools and manpower. The following specific items are required for this task:

• Silicone grease

• Torque wrench

• A crane capable of lifting the entire hull unit

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Note

The hull unit is heavy. Appropriate lifting equipment (lifting tackle, portable crane or ship’s crane) is required. Always use appropriate lifting equipment to minimize risk of personnel injury or equipment damages. Only certified equipment must be used.

Context

Note

The transducer face is covered with a red protective coating made of a special plastic type. The red protective coating is a vital part of the transducer. It is very important that neither this coating nor the internal parts of the transducer are damaged during the handling, installation or cleaning. Any holes and/or scratches in the transducer surface will allow water to penetrate the transducer. If a leak occurs, the transducer must be replaced.

A dedicated gasket is provided with the HiPAP Hull unit delivery. This gasket ensures a watertight connection between the installation trunk and the bottom of the transducer shaft sleeve. During the installation process, make sure that the gasket is kept safe from damage, and that the top of the installation trunk is kept clean, smooth and without physical damage such as scratches or dents. Proper O-ring lubrication must be applied before the hull unit is mounted on top of the installation trunk.

Procedure

1 Manoeuvre the unit into the hull unit compartment, taking care not to damage the unit.

The mating surface of the transducer dock flange must be protected at all times during the operation.

2 Raise the unit using two cranes/tackles, one of them must be attached to the top of the unit.

3 Rotate the unit to the upright position without any part touching the deck.

4 Once the entire weight of the unit is supported by the crane attached to the top of the unit, release the crane attached to the lower end.

The unit is now hanging from one crane.

5 Manoeuvre the unit over the gate valve.

6 Stop lowering when the bottom flange of the transducer dock approaches the gate valve.

7 Remove the protective cover from transducer dock and gate valve flanges, and check that the mating surfaces are clean and undamaged.

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8 Wipe a film of grease in its groove, and position the O-ring seal.

Use grease that have the properties from the Grease for shaft and chain specifications.

9 Carefully lower the hull unit down onto the gate valve.

Make sure that the studs mate correctly and easily with their corresponding holes in the transducer dock flange.

Make sure that the O-ring stays in place.

10 Place the nuts and washers onto all the stud bolts, making sure that the required washers are used.

11 Tighten all the nuts to finger tight, and then working alternately on opposite sides of the dock.

12 Tighten the nuts to the recommended torque.

13 The hull unit must be supported against the vessel’s hull in two directions 90° apart, using steel braces of suitable dimensions. These braces must be bolted into position to allow later maintenance or possible removal of the hull unit. Refer to the typical arrangement drawing, to see where and how many are required for the different hull units.

14 Make sure that no units or protrusions will obstruct the vertical movement of the hull unit or the transducer cables.

Installing the hoist motor

The hull unit is delivered with the motor dismounted. It must therefore be fitted during the installation.

Prerequisites

It is recommended to fit the motor after the hull unit has been installed in the vessel.

Procedure

1 Remove the plate covering the motor shaft key-way on the gearbox.

2 Mount the motor onto the gearbox using all the bolts provided.

3 Remove the oil filler and level plugs from the gearbox, and fill the gearbox with oil type SAE 30 if necessary.

4 Cut the plastic vent plug on the oil filler plug to allow the gearbox to breathe.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Installing the hull unit controller

The unit is designed to be mounted on a bulkhead.

Prerequisites

For safety reasons, the unit must be mounted such that the operator has a direct and unhindered line of sight from the cabinet to the hull unit.

Procedure

1 Determine the location of the unit.

2 Check on the other side of the bulkhead to ensure there will be no “surprises” when the holes are drilled or welding is performed.

3 Bore the holes to fit M8 bolts, or weld 4 x M8 studs to the appropriate positions on the bulkhead.

4 Lift the cabinet against the bulkhead and align the mounting holes/studs.

5 Locate the bolts/studs through the holes, place washers onto the threads, then screw nuts onto them.

6 Make sure the cabinet is positioned correctly, then tighten the nuts to the final torque.

Cable layout and interconnections

Further requirements

Connect the cables.

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Topics

Sonar room cable plan (Hull unit), page 30

Sonar room cable plan (Hull unit with gate valve control unit), page 31

List of cables, page 32

Installing the HiPAP Hull unit cables, page 32

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Sonar room cable plan (Hull unit)

The sonar room cables include those used to connect the HiPAP Hull unit units to AC mains power, as well as the control cables between the units.

Hull unit

Junction box

Hoisting motor

Hull unit controller

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Cable layout and interconnections

Sonar room cable plan (Hull unit with gate valve control unit)

The sonar room cables include those used to connect the HiPAP Hull unit units to AC mains power, as well as the control cables between the units.

Hull unit

Junction box

Hoisting motor

Hull unit controller

Gate valve power pack

Hydraulic pipes

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

List of cables

A set of cables is required to connect the system units to each other, and to the relevant power source(s). Additional cables are required to connect the HiPAP Hull unit system to peripheral devices.

Cable

C22

C28

C29

C30

C31

C32

C33

C34

C35

C36

C37

Type

Ethernet cable

From/To

From hull unit controller to transceiver

AC Power cable

Control cable

Ground cable

From hull unit controller to hoist motor

From hull unit controller to hull unit junction box

From hull unit controller to vessel ground

Transducer cable From hull unit to hull unit junction box

Control cable From hull unit controller to gate valve

Control cable

AC Power cable

From hull unit controller to gate valve

From hull unit controller to AC power outlet

AC Power cable

Control cable

From hull unit controller to gate valve power pack, Optional

From hull unit controller to solenoid, Optional

Minimum requirements

Cat 7

4 x 1.5 mm 2

6 x 0.75 mm 2

4 x 1.5 mm 2

2 x 0.75 mm 2

Installing the HiPAP Hull unit cables

Topics

Installing the system cables, page 33

Connecting power to the hoist motor, page 33

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Cable layout and interconnections

Installing the system cables

The sonar room cables include those used to connect the HiPAP Hull unit units to AC mains power, as well as the control cables between the units.

Procedure

1 Connect the power cable from the hull unit controller to the AC power outlet. (C34)

2 Connect the ground cable from the hull unit controller to vessel ground. (C30)

3 Connect the power cable from the hull unit controller to the hoist motor. (C28)

Connecting power to the hoist motor, page 33

4 Connect the control cable from the hull unit controller to the hull unit junction box. (C29)

5 Connect the control cable from the hull unit controller to the gate valve. (C32, C33)

6 Connect the power cable from the hull unit controller to the gate valve power pack. (C35)

7 Connect the cable from the hull unit controller to the solenoid. (C36)

8 Connect the cable from the hull unit controller to the solenoid. (C37)

Connecting power to the hoist motor

The hoist control unit provides the power to the hoist motor.

Prerequisites

The cable must be provided by the installation shipyard.

Hoist control unit

X1/4 (U1)

X1/5 (V1)

X1/6 (W1)

PE Rail

Signal

Ground

Hoisting motor

Ground

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Location of the Lower Limit Switch

Location of the Upper Limit Switch

Hoist control unit

Power

Procedure

1 Produce the cable according to the specification.

2 Connect the cable shield in PE ground.

3 Connect the cable to the Hoist Control Unit (C) according to the wiring specification.

4 Select the cable to be connected into the cabinet, and select the cable gland through which the cable is to pass.

5 Take care not to damage the screening. Carefully remove the outer insulation from the required cable length.

6 Run the cable to the Hoist motor (D) .

7 Remove the 10 screws on the Hoist motor.

8 Lift off the lid.

9 Remove the blind plug at the bottom of the motor.

10 Run the cable through the cable gland.

11 Connect the cable according to the wiring specification.

12 If it is a 440 V power supply then connect cable where it is labelled 440 V supply.

13 If it is a 220 V power supply then connect cable where it is labelled 220 V supply.

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Operating procedures

Topics

Maximum speed, page 36

Lowering the transducer, page 36

Raising the transducer, page 37

Manual operation of the hull unit, page 37

Preservation of units, page 38

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Maximum speed

It is important to monitor the vessel speed and the water depth when the transducer is in the lowered position.

Note

When the transducer is lowered, the depth of water under the vessel must be monitored closely. Take note of the recommended vessel speed.

Hull Unit

HL 2180

HL 3770

HL 4570

HL 6120

Maximum speed

10 knots

8 knots

6 knots

Lowering the transducer

It is important to monitor the vessel speed and the water depth when the transducer is in the lowered position.

Prerequisites

Before you start moving the hull unit.

• Make sure that there is no maintenance work going on.

• Make sure that nothing is blocking the hull unit which could prevent it from moving or jam it while it is moving.

For operating the hull unit from the hull unit controller, make sure the button on the unit points to LOCAL .

For operating the hull unit from the computer, make sure the button on the unit points to REMOTE .

Procedure

1 Open the gate valve.

Select Gate valve open on the hull unit controller or the computer.

2 Lower the transducer.

Select TD down on the hull unit controller or the computer.

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Operating procedures

Raising the transducer

It is important to monitor the vessel speed and the water depth when the transducer is in the lowered position.

Prerequisites

For operating the hull unit from the hull unit controller, make sure the button on the unit points to LOCAL .

For operating the hull unit from the computer, make sure the button on the unit points to REMOTE .

Procedure

1 Raise the transducer.

Select TD up on the hull unit controller or the computer.

2 Close the gate valve.

Select Gate valve close on the hull unit controller or the computer.

Manual operation of the hull unit

It is important to monitor the vessel speed and the water depth when the transducer is in the lowered position.

Prerequisites

When the transducer must be raised or lowered for maintenance purposes, you must use physical button on the hull unit controller. The hull unit controller is near the hull unit and the operator has a clear view of the hull unit while it is being raised or lowered. The operator is then in a much better position to start and stop the hull unit as required.

Make sure that there are no obstructions around the hull unit that could prevent it from moving or jam it while it is moving.

Make sure that the power to the hull unit is switched off before using the hand crank.

Context

A hand crank is provided for a manual operation and it is stored on the side of the gallow.

Attach the hand crank to one end of the motor shaft and raise or lower the transducer manually in the event of a power failure or for maintenance purposes. The motor has an internal brake mechanism which must be released manually before using the hand crank.

Procedure

1 Loosen the hand crank from the hoist platform.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

2 Move the hand crank to the side of the motor.

3 Tighten the brake screw on top of the motor/gearbox until you are able to turn the motor shaft with the hand crank.

4 Loosen the brake screw when you are done moving the hull unit.

5 Move the hand crank to the side of the gallow for storage.

Note

It is important to remember to store the hand crank on the side of the gallow when you have finished the manual operation. Not storing it in the correct place might cause damage to people and the hull unit.

Preservation of units

Mounting flange

After welding completion all exposed surfaces must be painted with primer and topcoat, and antifouling where appropriate. Damaged paint must be repaired.

The mating surface of the flange unit must be protected with a wooden cover at all times till the gate valve is about to be installed.

Gate valve

Keep the gate valve in its transport protection until the start of installation. The mating surface of the gate valve must be protected with a wooden cover at all times till the gantry is about to be installed. Make sure the limit switches are protected from mechanical damage as well as from dirt or liquids.

Gantry

The mating surface against the gate valve must be protected with a wooden cover at all times till the gantry is about to be installed. Transducer cable should be strapped along the gantry until it is to be connected to the transceiver, and wrapped with the gantry in dust and heat resistant material during the building period at yard.

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Operating procedures

Hoist control and transceiver unit

The units should be kept closed at all times when not operated. The units should be wrapped in heat and dust resistant material during any welding, grinding, painting or cleaning work nearby.

Cables

All installed cables to be securely routed in trays, protected from being stepped on or damaged by falling objects or particles.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Testing the operating functionality of the system

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Electrical check of hull unit and limit switches

This procedure checks the electrical operation of the hull unit and sets up the limit switches.

Prerequisites

It must be performed after all inspections, cable connection checks and the manual operation check have been performed, but before the hull unit is operated under power for the first time.

Context

A minimum of two experienced engineers from the yard’s quality assurance department and an Installation supervisor.

Procedure

1 Open the Gate Valve.

2 Lower the transducer manually by using the hand crank. Approximately 50 cm down.

Note

Remember to release the brake.

3 Remove the hand crank.

4 Switch power on, using breaker F01 on the hoist control unit (HCU).

5 Switch S1 in the HCU to HOIST and then STOP in rapid succession.

The transducer shaft should move upwards. If the transducer moves downwards interchange two leads of the motor supply.

6 Switch to LOWER .

7 After a few seconds, operate the lower limit switch manually.

Verify correct function of the switch. Lowering transducer should stop when operating the limit switch.

8 Switch to HOIST .

9 After a few seconds, operate the upper limit switch manually.

Verify correct function of the switch. Raising the transducer should stop when operating the limit switch.

10 Switch to HOIST . Let the transducer move all the way up to the fully raised position.

Note

Check the water depth/clearance under the ship/transducer before proceeding!

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

11 Switch to LOWER .

Let the transducer go all the way down to the fully out position.

12 Switch to HOIST .

Let the transducer go all the way up to the fully raised position.

13 Release any air which may have accumulated in the transducer dock and shaft sleeve using the air vent valve.

14 Set switch S1 to REMOTE .

This to check remote operation, using the Remote Control Unit (RCU).

The RAISE/UP and STOP lamps on the RCU should light.

15 Press LOWER/DOWN and monitor the lowering of the transducer.

16 After a few seconds, press STOP .

The STOP lamp shall be lit.

17 Press LOWER/DOWN .

18 After a few seconds, press the Test button on the protection relay (F02), in the hoist control unit (HCU).

The STOP lamp shall be lit.

19 Press the Reset button (blue) on the protection relay (F02), in the hoist control unit (HCU).

20 Press LOWER/DOWN .

21 Verify that the LOWER/DOWN and STOP lamps are lit when the lower limit is in fully out position.

22 Press RAISE/UP , and monitor the raising of the transducer.

Verify that the RAISE/UP and STOP lamps are lit when the transducer is in the fully raised position.

23 Check that the lamp dimmer operates correctly.

Result

Test certificate

Items to be checked

DOWN/UP function – local

Lower limit switch

Upper limit switch

DOWN function – remote

STOP function – remote

UP function – remote

Checked (Signature)

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The installation of the hull unit has been checked according to the procedures defined in this manual. Comments concerning inaccuracies, faults and/or poor workmanship have been filed as a separate report.

Yard’s quality assurance department

Signature and date

Installation team supervisor

Signature and date

Manual check of hoisting and lowering the hull unit

This procedure is a mechanical test during which the hull unit is operated manually.

Prerequisites

Note

Before lowering the hull unit, ensure there is a sufficient depth of water beneath the vessel’s hull. If the vessel is in dry dock, check in the hull unit compartment and under the vessel to ensure no-one is working on the equipment and there are no obstructions.

Rope off the area under the hull to ensure no one goes into the area while the hull unit is being operated.

An experienced engineer from the yard’s quality assurance department and an Installation supervisor is needed for this procedure.

Context

This test checks that the hull unit is free to move without striking any obstructions and that the transducer cables are not going to become caught on anything during the lowering and raising operations. This check is to be used before the hull unit is powered up for the first time, and after any major maintenance or replacement has been carried out on the unit.

Procedure

1 Check around the hull unit and ensure there are no obstructions liable to hinder the lowering or raising of the unit.

2 If the vessel is in a dry dock, check under the vessel to ensure the transducer will not strike an obstruction when it is lowered.

3 Remove the hand crank lever from the hoist platform and place it in position on the hoist motor shaft.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

4 Release the motor brake by tightening the screw on the side of the motor, and lower the transducer approximately 30 cm.

5 Reset the brake by slackening the screw.

6 Check that the cable is free to follow the transducer shaft as it is lowered, and is not liable to be caught on any obstructions.

Remember that the cable may swing some distance from the hull unit in rough seas, so check to the full radius of the cable.

7 Repeat steps 1 to 6 until the hull unit is fully lowered.

8 Follow the same procedure to raise the hull unit again, paying particular attention to the cable.

9 If the vessel is floating, release any air which may be trapped in the mounting flange by cracking open the air vent valve.

Result

Test certificate

Items to be checked

Manually (by hand crank) lower/rise transducer shaft

Transducer cable free to move

Checked (Signature)

Yard’s quality assurance department

Signature and date

Installation team supervisor

Signature and date

Checking the cable installation

This is the test procedures for the system’s power and signal interface cables.

Prerequisites

Note

These checks must be completed before any power is switched onto the system.

An experienced engineer from the yard’s quality assurance department and an Installation supervisor is required for this procedure.

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Context

Visual inspection of the cabling

Refer to the cable plans and interconnection diagrams, and check all power and inter-connection cables. Any locally fitted plugs and connectors must also be checked to ensure the correct types have been used for the specific locations. (Sealed/spark-proof connectors in areas where flammable gasses may accumulate, etc.)

• Ensure all cable connections have been made according to the cable plan, and that all connections are tight and secure.

• Ensure all cables are correctly laid in conduits, or are otherwise protected according to the regulations and recommendations laid down by the vessel’s registering authority.

• Ensure all protective covers are fastened correctly.

Cable connections and continuity

After the cable connections have been completed and the visual inspection has been carried out, all the cable wires must be checked for correct connection and continuity.

Refer to the cable plans and interconnection diagrams, and check all interconnection cables. Any locally fitted plugs and connectors must also be checked for shorts or open circuits.

• Ensure all cable connections have been made according to the cable plan, and that all connections are tight and secure.

Note

The exact resistance values will depend on the type and lengths of the cables and the units to which the cables are connected. If in doubt, check with the manufacturers.

Procedure

1 The test engineers must position themselves one at each extremity of the cable to be checked.

2 Good communications must be established.

3 Ensure the cable to be tested is not connected to any power source.

Note

If a cable terminates in a plug at the unit, the test will be more easily conducted if the plug is disconnected.

4 Select one pair of cable wires, and check that the wires are connected to the correct terminals in the unit.

5 The tester then connects his continuity tester to the two terminals in question and checks the continuity.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Note

If a low resistance (i.e. <100Ω-10kΩ) exists between the two wires, this may indicate the cores are connected to circuits or units with low internal resistance. If this is the case, disconnect the wires from the terminal block and test again. The assistant then removes the shorting strap, and the resistance should go up to ≈ ∞ Ω again.

6 The assistant then shorts the two wires together, and the tester repeats the test.

The resistance should be ≈ 0 Ω.

7 The assistant then removes the shorting strap, and the resistance should go up to

≈ ∞ Ωagain.

8 The tester then checks each core’s resistance to ground, (this should be ≈ ∞ Ω), and each core’s resistance to all the other wires in the cable, (this should be ≈∞ Ω).

9 Assuming the test results are correct, the wires must then be reconnected to the terminal block (if they had been removed), and the terminals checked to ensure they are correct and tight.

10 On completion, move on to the next pair of wires and repeat the tests till the entire cable has been checked.

Result

Test certificate

Items to be checked Checked (Signature)

Connector type

Cable continuity

Yard’s quality assurance department

Signature and date

Installation team supervisor

Signature and date

Inspection of the hoist control unit

The hoist control unit (HCU) is installed as close as possible to the hull unit.

Prerequisites

An experienced engineer from the yard’s quality assurance department and an Installation supervisor is required for this procedure.

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Procedure

1 Perform a close visual inspection of the cabinet.

2 Check that the unit is installed in the correct location, and is suitably orientated to enable easy maintenance.

3 Check that the unit is not damaged, and that the paintwork is clean.

4 If the unit is secured to mounting brackets, check that the brackets are manufactured correctly and are bolted or welded securely to the bulkhead.

5 If bolts have been used, ensure they are of an appropriate size and number to ensure the brackets are secure.

6 If the brackets are welded, ensure the welds are satisfactory and strong enough to hold the brackets and unit.

7 Check that the cabinet is securely fastened to the bulkhead/mounting brackets.

8 Check that the correct flat and shake-proof washers have been used, and that all the bolts are tight.

9 Check that the braided ground conductor is correctly installed.

10 Check that all welds/brackets have been painted with the correct preservation medium to prevent corrosion.

Result

Test certificate

Items to be checked Checked (Signature)

Bolted/Welded

Bolts/ground conductor correct

Paintwork correct

Yard’s quality assurance department

Signature and date

Installation team supervisor

Signature and date

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Checking the hull unit installation

After the installation has been completed, all parts of the Hull unit must be checked to ensure a secure and safe installation. These checks must be performed before the system is switched on for the first time.

Prerequisites

An experienced engineer from the yard’s quality assurance department and an Installation supervisor are required for this procedure.

Context

Start at the bottom of the unit.

Refer to the installation drawings and cable diagrams in the Drawing file chapter of this manual, and any relevant drawings and procedures which may have been prepared for the vessel by the yard.

Procedure

1 Perform a close visual inspection of the vessel’s hull, both internally and externally, in the area around the mounting flange.

2 Check that the hull plates have not buckled during the cutting and welding processes. Check that hull strengthening plates have been fitted as per the drawings, and that all welds are strong and watertight.

3 Ensure that all exposed metal surfaces have been properly painted with the appropriate preservation mediums to prevent corrosion.

4 Perform a close visual check of the mounting flange installation.

Ensure that the unit is mounted properly, that all joints are satisfactory and that the unit has been correctly braced to the vessel’s hull.

Note

If the installation of this part of the hull unit is not correctly performed, the safety of the vessel will be compromised.

5 Ensure the unit is mounted properly using the o-rings provided and the correct type and number of bolts, nuts and washers.

6 Ensure all the bolts are correctly tightened.

7 Ensure the painted parts are properly painted with the appropriate preservation mediums to prevent corrosion.

8 Check that the hull unit assembly is correctly orientated and installed, and that the upper part of the gantry is suitably supported to the hull with reinforcing braces.

9 Check that the braces are BOLTED into position, NOT WELDED .

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10 Ensure all nuts and bolts used are suitable for the application, and that the appropriate flat and shake-proof washers are used.

11 Ensure all nuts and bolts are correctly tightened.

12 Ensure all applicable metal surfaces are properly painted with the appropriate preservation mediums to prevent corrosion.

13 Ensure the guide rails, sprockets and drive chains within the gantry have sufficient grease to ensure smooth raising and lowering of the shaft.

14 Wipe off any excess grease.

15 Check that there is sufficient grease in the shaft sleeve.

When sufficiently filled, a thin film of oil should be noticeable on the transducer shaft as it is raised. Oil filling and level plugs are located on the side of the shaft sleeve. Check that the filler and level screws are tight and not leaking. Clean up any oil spillage.

16 Check that the limit switches are properly secured into the gantry.

Limit switch operation will be checked during the "Setting to work" phase.

17 Check that the self-locking electric motor is correctly mounted, and that all securing bolts are tight.

18 Find the hand crank stowed on top of the hull unit, and check that the hand crank fits in position on the hoist motor shaft.

19 Replace the hand crank into position.

20 Check that the motor gearbox is filled with oil, and that there are no oil leaks.

Result

Test certificate

Items to be checked

Hull unit installation and preservation correct

Mounting flange installation and preservation correct

Gate valve installation and preservation correct

Gantry installation and preservation correct

Guide rail, sprockets and drive chains lubricated

Sleeve filled, no oil leaks

Limit switches correct

Motor and hand crank correct, gearbox full and sealed

Checked (Signature)

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Yard’s quality assurance department

Signature and date

Installation team supervisor

Signature and date

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Adjusting the drive chain tension, page 52

Topics

Replacing the drive chain, page 52

Replacing the gate valve, page 53

Replacing the transducer cable, page 54

Replacing hoist control unit parts, page 56

Replacing the hoist motor’s gear box, page 57

Lifting the hull unit (without a service dock) to access the transducer, page 58

Disassembling the shaft sleeve, page 59

Inspecting and replacing zinc anodes, page 61

Adjusting the guide rails on the gallow, page 62

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Adjusting the drive chain tension

The drive chains transmit the force from the hoist motor to the transducer shaft, to raise or lower the shaft.

Context

Procedure

1 Slacken lock-nut A on tension adjustment bolt B .

2 Slacken sprocket bearing nut C by 1/2 turn.

3 Adjust tension adjustment nut D to achieve the correct tension in the chain.

4 Tighten the sprocket bearing nut and the lock-nut.

5 Check the chain tension. It may have altered as the nuts were tightened.

Replacing the drive chain

Replace both drive chains at the same time.

Context

Procedure

1 Slacken the chains by loosening the lock-nut A and slackening the sprocket bearing nut C .

2 Find and remove the joints, and disconnect the chains from the transducer shaft.

3 Replace the chains.

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4 Adjust the tension.

Replacing the gate valve

The gate valve closes the opening in the vessel’s hull when the transducer is raised.

Prerequisites

This task must take place in dry dock.

The tools needed for this procedure is two winches or cranes. One for the hull unit which weighs 1500 kg and one for the gate valve which weighs 500 kg.

Three or four trained maintenance engineers/fitters are needed for the maintenance work.

Context

The hull unit must be lifted to enable the old gate valve to be taken out and a new valve to be fitted. Check that all electrical cables to the hull unit have enough slack such that they will not be placed under tension as the hull unit is lifted.

Note

If an hydraulic actuator (optional) is fitted, it must be removed before you take out the gate valve.

Procedure

1 Fully raise the transducer.

2 Mount a suitable lifting apparatus to the deck head above the hull unit, and attach it to the top of the hull unit.

3 Remove all the gantry braces, and disconnect cables as necessary.

4 Take the weight of the hull unit on the lifting apparatus.

5 Remove the upper and lower mounting nuts/bolts to unbolt the gate valve from the transducer dock and the mounting flange.

6 Lift the hull unit clear of the gate valve.

7 Pull the old gate valve out.

Note

The gate valve is heavy. Lifting apparatus will be required.

Great care must be exercised to ensure the mating surfaces of the mounting flange and the transducer dock are not damaged.

8 Clean the mating surfaces and replace all O-rings.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

9 Move the new gate valve into position and lower it carefully onto the mounting flange.

10 Check that it is aligned correctly, and then secure it into position.

11 Lower the hull unit onto the gate valve.

Check that it is aligned correctly, and then secure it into position.

12 Replace all the gantry braces.

13 Check all electrical cables and connections.

Further requirements

Perform the system test.

Replacing the transducer cable

The transducer cable is connected to the transducer and the junction box.

Prerequisites

The power must be switched off to the Hoist control unit and the Transceiver unit before the maintenance work can begin.

Procedure

1 Open the transducer dock.

2 Remove the transducer.

3 Remove the four “extended-head” bolts securing the support plate.

Access is through the four holes in the plug plate.

4 Remove the eight bolts located around the circumference of the connector plate.

The connector plate should now be free.

5 Open the junction box at the top of the transducer shaft.

6 Disconnect the flat cables.

7 Remove bolts from nipple plate at the rear side of the junction box.

8 Remove the six socket-head screws that secure the two half-ring plates in position on the top of the transducer shaft.

9 Remove the two half-ring plates.

10 Pull up the upper gland block and remove the o-ring.

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This will reduce the likelihood of the o-ring being damaged and will reduce the force required to pull the block down the shaft.

It should now be possible to pull and feed the transducer cable down the transducer shaft and out at the transducer dock.

11 Tie a suitable length of rope to the upper connector plate.

12 Withdraw the cable through the transducer dock.

13 Check the O-rings on the upper gland block on the new cable, replace as necessary.

Leave the O-rings on the cable above the gland block to reduce the pull required and reduce the likelihood of damage as they are pulled up the shaft.

14 Tie the rope to the transceiver connector on the new cable and carefully pull the cable up through the shaft.

15 Once the connector is accessible at the top of the shaft, remove the rope and continue to pull the cable up by hand.

16 At the appropriate time, feed the upper gland block into the bottom of the shaft.

17 Orient the seal plate correctly, locate it in the bottom of the shaft, and then secure it using the four "extended head" screws.

18 Remove the four spacer screws (located beside the access holes for the "extended head" screws).

19 Orient the connector plate correctly, locate it in the bottom of the shaft, and secure it using the eight screws.

Note

The connector plate must be "floating".

Do not use any washers or packing pieces here. If the screws must be replaced, ensure the new screws are the same length. The connector plate must be loose to allow some movement as the connectors on the cables and the transducer mate.

20 Remove any twists from the cable in the shaft.

21 Lift the upper gland block up out of the shaft and fit the O-rings.

22 Orient the upper gland block correctly a fit it into the top of the shaft, and then b replace the two half-rings to hold the block in position.

23 Replace the six socket-head screws to secure the half-rings in position.

24 Connect the cable in the junction box.

25 Close the junction box.

26 Reinstall the transducer.

27 Close the transducer dock.

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Further requirements

Perform a system test.

Replacing hoist control unit parts

The relays and switches within the unit can be replaced individually. The replacement procedures for these items are similar.

Prerequisites

Inform the system supervisor that the system will be out of use while maintenance is performed.

Switch off all power to the system and remove the system fuses on the ship’s supply.

Procedure

1 Open the door to the cabinet.

2 Identify the defective unit.

3 Attach identification labels to all cables connected to that unit, and the terminals to which those cables are connected.

4 Disconnect the cables.

5 Detach the unit by slackening/removing the appropriate screws and/or detach the unit from the mounting rail.

6 Mount the replacement unit and reconnect the wires.

7 Check the connections against the circuit diagram to ensure they are correct.

8 Check the cabinet to ensure that all connections are tight.

9 Remove all tools and rubbish.

10 Close the cabinet door correctly.

11 Take the appropriate safety measures, and then replace the fuses.

12 Apply power to the system.

Further requirements

Perform a system test.

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Replacing the hoist motor’s gear box

Context

Procedure

1 Switch off power to the system in the hoist control unit.

2 Clamp the transducer shaft to prevent it from sinking when the motor is disconnected.

3 Slacken the drive chains and lift them off the drive sprockets.

4 Support the motor and gearbox unit and remove the four mounting nuts/bolts/washers B which secure the gearbox to the motor platform on the hull unit gantry.

5 Lift the motor/gearbox off the top of the hull unit and place it on a clean, stable work bench.

6 Remove the sprocket wheels from the drive shaft using a wheel puller.

7 Fit the sprocket wheels onto the new gearbox.

8 Move the motor to the new gearbox if necessary.

9 Lift the motor/gearbox assembly onto the hull unit motor platform and secure it in position using the four mounting nuts/bolts/washers B .

10 Lift the drive chains onto the sprocket wheels, and then check/adjust the tensions in the chains.

11 Reconnect the electrical cables.

12 Remove the transducer shaft clamp.

13 Perform the system test as described in the Test and alignment procedures chapter.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Lifting the hull unit (without a service dock) to access the transducer

If the hull unit does not have a transducer service dock, the entire hull unit must be lifted off the gate valve to gain access to the transducer.

Prerequisites

Three to four trained maintenance engineers/fitters are required for this procedure.

Procedure

1 Raise the transducer to the fully retracted position.

2 Switch off power to the system at the hull unit controller.

3 Close the gate valve, and perform the water-tightness test and drain the service dock.

4 Write down the colour coding and connections, then remove all electrical cables to and from the hull unit.

5 Secure a tackle capable of lifting the entire hull unit (1500 kg) to the deck head above the hull unit, and attach the tackle to the unit using the lifting eyes provided.

6 Tighten the lifting tackle, taking the weight of the hull unit.

7 Mark the positions of the bracing beams and the transducer dock relative to the gate valve to minimize changes in the hull unit alignment.

8 Remove the bracing beams supporting the hull unit.

9 Remove the bolts attaching the transducer dock to the gate valve flange.

The remaining water content of the dock will leak out but not under pressure. The dock must remain attached to the unit to protect the transducer.

10 Carefully hoist the hull unit off the gate valve.

The hull unit must be supported to ensure it does not swing if the vessel moves.

Protect the gate valve with a wooden cover to ensure the mating surface is not damaged during the operation.

If there is not enough headroom above the unit to enable it to be raised high enough for the engineer to gain access to the transducer the unit may be laid flat on the deck alongside the gate valve.

11 Lower the transducer using the hand crank until the transducer is fully exposed.

If the motor is not accessible for manual operation, the transducer dock may have to be removed to gain access.

12 Perform the required maintenance routines.

13 On completion of the maintenance work, ensure that no rubbish, tools etc. have been left in the dock, and then replace the hull unit by following the above procedure in reverse.

14 Tighten all the bolts to the correct torques.

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15 Reconnect all the electrical cables.

Further requirements

Perform a system test.

Disassembling the shaft sleeve

The shaft sleeve is located at the bottom of the hull unit gantry.

Prerequisites

If the shaft sleeve must be disassembled for any reason, you are strongly recommended to ask for assistance from Kongsberg Maritime. If the transducer adapter is not replaced correctly, you risk losing the transducer.

Two trained maintenance engineers/fitters are needed for performing this procedure.

Entering tools are also needed.

Context

To prevent water leakage and to ensure smooth raising and lowering of the transducer, the shaft sleeve is fitted with:

At the upper end – Lion twin-set packing seals.

At the lower end – U-cup packing seals and a scraper.

The space between the seals is filled with grease to lubricate the shaft and provide extra watertight security.

When the sleeve is sufficiently filled, a thin film of grease will be observable on the transducer shaft.

Note

It is important that the shaft sleeve is kept watertight, and that the transducer shaft raising and lowering actions are as smooth as possible. If the system is in frequent use, the shaft sleeve may be exposed to sea growth, dirt and pollution as the transducer shaft is raised. Frequent inspections, and greasing when necessary, are strongly recommended.

Procedure

1 Switch off power to the system on the Hoist Control Unit.

2 Dismount the hull unit.

3 Lower the transducer manually, and clean it using a stiff, plastic-bristled brush and copious amounts of water. On completion, dry the unit carefully.

4 Remove the transducer from the end of the shaft.

5 Disconnect and remove the transducer cable.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

6 Remove the transducer adapter from the end of the shaft.

7 Remove the transducer dock from the hull unit.

8 Loosen the nuts/bolts holding the upper and lower clamping rings to decompress the seals, and remove the shaft sleeve from the hull unit.

9 Replace the upper shaft bearing and seals as follows: a Remove the six nuts holding the upper gland clamping ring onto the sleeve.

b Lift off the upper gland clamping ring.

c In preparation for replacement, unscrew the six spacing bolts till the ends of the threads are flush with the surface of the clamping ring.

d Extract the two parts of the upper sleeve seal and the upper sleeve bearing from the sleeve.

e Clean the grease from the upper (internal) part of the shaft sleeve.

f Use the entering tool, and fit a new upper shaft bearing and seals into the top of the sleeve.

g Place the upper clamping ring in position and secure it loosely using the nuts.

10 Replace the lower shaft bearing and seals as follows: a Remove the six socket-head screws securing the lower clamping ring onto the bottom of the shaft sleeve, and then remove the ring.

b Use the entering tool and extract the lower sealing ring and the lower shaft bearing.

c Clean the grease from the lower (internal) part of the shaft sleeve.

d Fit a new lower shaft bearing using the entering tool, and new lower shaft seal, ensuring they are correctly orientated.

e Fit a new scraper ring into the lower clamping ring.

f Locate the lower clamping ring on the bottom of the shaft sleeve, and hold it loosely in position with the six socket-head screws.

11 Mount the shaft sleeve onto the hull unit gantry.

Note

Ensure the shaft passes smoothly through the bearings and seals. If the seals are pinched or otherwise damaged, they must be replaced.

12 Mount the transducer dock onto the shaft sleeve.

13 Replace the transducer adapter onto the bottom of the shaft.

Ensure the holes and bolts are scrupulously clean and all traces or grease and old

Loctite are removed.

Use new o-rings. Use Loctite 577 on the bolts, and tighten the bolts to final torque.

14 Using new O-rings and lock washer, remount the transducer.

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15 Install the hull unit onto the gate valve.

16 Ensure the gantry is correctly orientated, then bolt it firmly into position and refit the gantry braces.

Ensure that the gantry is replaced as exactly as possible in its original position.

17 Tighten all the mounting bolts for the dock, shaft sleeve and gantry to the appropriate torques.

18 Tighten the six socket-head screws holding the lower clamping ring onto the shaft sleeve to final torque.

19 Tighten the upper shaft seals against the shaft by tightening the six nuts around the upper clamping ring.

20 Once the upper seals are tight, tighten the six spacing bolts to fix the pressure on the seals.

21 Refill grease.

22 If required, adjust the tension.

Further requirements

Perform a system test to ensure the hull unit operates correctly.

Inspecting and replacing zinc anodes

The anodes are bolted to the underside of the shaft sleeve and at the bottom of the service dock.

Prerequisites

Two trained maintenance engineers/fitters are needed to perform this procedure.

Procedure

1 Switch off power to the system at the hoist control unit.

2 Open the transducer dock.

3 Clean the transducer and transducer dock using a stiff, plastic-bristled brush and copious amounts of water.

4 Inspect the anodes.

There are four anodes in total. Two are bolted to the underside of the shaft sleeve and two at the bottom of the service dock.

If the anodes are severely corroded, replace them. If not, assess the extent of the corrosion and the time since the previous inspection, and estimate when the anodes will require replacing.

Plan another inspection some time before the anodes will need to be replaced.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

5 Replace the anodes if needed.

6 On completion, close the transducer dock.

Adjusting the guide rails on the gallow

The guide rails ensure the transducer is aligned correctly.

Context

When the shaft is fully lowered there must be no space between the guide rails and the adjustable sliders.

Procedure

1 Fully lower the transducer shaft.

2 Slacken the lock nuts and adjust the sliders until they are tight against the guide rails.

3 Tighten the lock nuts and re-check the clearance.

4 Raise the transducer shaft and check the clearances at several places as it is raised.

If the clearances between the sliders and the rails changes (2/3) as the shaft is raised, the rails will need to be adjusted.

Note

These adjustments could affect the system alignment. If in doubt, contact Kongsberg

Maritime AS for assistance.

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Preventive maintenance schedule, page 64

Topics

Cleaning the hull unit, page 64

Inspecting and cleaning the transducer face, page 66

Watertightness test, page 67

Open/close gate valve, page 68

Lubricating the drive chain, page 68

Lubricating the shaft sleeve, page 69

Hull unit inspection, page 70

Hoist control unit inspection, page 71

Checking and filling gear oil, page 72

Preservation of units, page 72

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Preventive maintenance schedule

In order to secure a long and trouble-free operation of the HiPAP Hull unit system, certain specific preventive maintenance tasks must be done. The tasks are organized in a preventive maintenance schedule .

• Every second week, if possible

– OPEN/CLOSE gate valve

• Regularly, depending on marine growth

– Clean HiPAP transducer

• Every second month

– Lubricating drive chains/sprockets

– Cleaning transducer shaft

• Every 6th month

– Inspection of junction box

• Annual

– Hull unit, general inspection

– Filling motor gearbox

– Filling shaft sleeve

– Hoist control unit, general inspection

– Actuator

Cleaning the hull unit

The hull unit has normally been exposed to a salt atmosphere. Prior to storage and/or shipment, it must be thoroughly cleaned to prevent corrosion.

Prerequisites

In order to clean the hull unit, you will need relevant tools and detergents.

Context

For all practical purposes, the hull unit comprises to separate areas; the “wet parts” and the “dry parts”.

• The “wet parts” include the lower part of the transducer shaft, the installation trunk, the bottom of the mounting flange, the zinc anodes and the transducer. These parts are all exposed to the sea.

• The “dry parts” are the rest of the hull unit, all contained inside the hull. This includes the electric motor and the Motor Control Unit.

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A transducer must always be handled as a delicate instrument. Incorrect actions may damage the transducer beyond repair. A physical blow to the transducer face may easily damage one or more elements. Observe these transducer handling rules:

• Do not activate the transducer when it is out of the water.

• Do not handle the transducer roughly. Avoid impacts.

• Do not expose the transducer to direct sunlight or excessive heat.

• Do not damage the outer protective skin of the transducer.

• Do not use high-pressure water, sandblasting, metal tools or strong solvents to clean the transducer.

• Do not step on the transducer cables.

• Do not damage the transducer cables. Avoid exposure to sharp objects.

Procedure

1 Wash the “wet parts” of the hull unit using a high-pressure hose and copious amounts of fresh water.

Caution

Do not use direct the high pressure water directly towards the transducer. Observe the handling rules!

2 Ensure that all traces of mud and marine growth are removed.

Use a wooden or plastic scraper to remove persistent growth, barnacles etc.

3 Wipe off the external surfaces of the “dry parts” of the hull unit using a damp lint free cloth and a mild detergent.

Note

Do not use excessive amounts of water. The “dry parts” of the hull unit includes parts that are not water tight.

4 On completion, dry the unit thoroughly.

5 Inspect all surfaces for signs of corrosion, flaking, bubbling paint, stains etc.

6 Clean damaged or suspect areas, prepare and preserve these areas using the correct preservation mediums.

7 Wipe clean all exposed cables, and check for damage.

If a cable shows signs of wear or ageing, contact Kongsberg Maritime for advice.

8 Secure and protect loose parts.

9 If the hull unit shall be sent to storage or shipped, spray it externally using a corrosion inhibitor (for example a light oil) prior to packing.

10 If relevant, place a suitably sized bag of desiccant material (silica gel or similar) into the to storage/transport box to keep the components as dry as possible.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Inspecting and cleaning the transducer face

Marine growth (biological fouling) on the transducer face reduces the performance. For this reason, it is important to keep the transducer face clean. Every time your vessel is in dry dock, you must remove the marine growth. At the same time, you must inspect the transducer closely for physical damage.

Prerequisites

The following tools and consumables are required:

• Personal protection

• Fresh water

• A mild synthetic detergent and a plastic brush

• A piece of wood or plastic without sharp corners

• Citric acid (<50%) (only if required)

Context

During normal use, the transducer is subjected to biological fouling. If this marine growth is excessive, it will reduce the overall performance of your system. Whenever opportunity arise, typically when the vessel is dry-docked, the transducer face must be cleaned for shells and other marine growth.

It is important to check the transducer for physical damage. Any cracks, fractures or holes in the red protective coating may result in a water leak, and a leak may cause irreparable damage to the transducer.

A transducer must always be handled as a delicate instrument. Incorrect actions may damage the transducer beyond repair. Observe these transducer handling rules:

• Do not activate the transducer when it is out of the water.

• Do not handle the transducer roughly. Avoid impacts.

• Do not expose the transducer to direct sunlight or excessive heat.

• Do not use high-pressure water, sandblasting, metal tools or strong solvents to clean the transducer.

• Do not damage the outer protective skin of the transducer.

• Do not damage the outer protective skin of the transducer face.

• Do not step on the transducer cable.

• Do not damage the transducer cable. Avoid exposure to sharp objects.

Procedure

1 Allow for sufficient access to clean and inspect the entire surface of the transducer.

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2 Remove biological fouling carefully using a plastic brush, a suitable synthetic detergent and fresh water.

Biological material which is strongly rooted in the substrate can be removed carefully with a piece of wood or plastic. If required, you can also use citric acid.

Apply, leave it working for several hours, and rinse thoroughly with fresh water.

Note

Do not use high-pressure water, sandblasting, metal tools or strong solvents to clean the transducer.

Do not damage the outer protective skin of the transducer face.

3 Allow the transducer surface to dry.

4 Do a thorough visual inspection of the transducer.

Check for dents, scratches, holes or other damage to the surface.

If you find suspicious damage, take high resolution photos that show the damage.

Contact your dealer or the Kongsberg support organization for advice.

5 If necessary, apply anti-fouling paint as described in the dedicated procedure.

Note

Because some paint types may be aggressive to the polyurethane in the transducer, consult our list of approved paints.

Watertightness test

Every time maintenance is done that involves breaking the watertight integrity of the hull unit, the watertightness must be tested to make sure nothing will happen during the maintenance.

Procedure

1 Hoist the hull unit to the upper limit.

2 Switch off all power to the system.

3 Close the gate valve.

4 Check that the gate valve is sealed, by opening the air-vent cock on the top of the transducer dock.

A small amount of water should flow out as the pressure within the transducer dock equalises with the ambient air pressure.

5 Crack open the gate valve and close it again, when the water stops flowing.

Water should start flowing out of the air-vent when the valve is cracked open, and should cease soon after it is closed again. This action will prove that the lack of

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HiPAP 602/502/452/352/102 Hull unit Instruction manual water flow is because the gate valve is sealed, and not merely because the air-vent cock is blocked.

Result

Once the test has been performed satisfactorily, you can assume that it is safe to continue with the required maintenance routines.

Caution

If for any reason there is a delay between performing the watertightness test and starting the maintenance, play safe - perform the test again.

Open/close gate valve

The gate valve needs to be moved, to stay watertight.

Context

The surfaces of the gate valve are subjected to biofouling and sediment build up.

Biofouling that has been allowed to pass the initial attachment phase, can only be mechanically removed. To minimize this, the valve must be operated at regular intervals.

For hydraulic operated valves, use the hand pump to make sure you have proper surface engagement.

Minor leaks are to be expected over time. Leakage rate up to 3 litres per minute is no obstacle for performing transducer maintenance and repair.

The gate valve should be moved every two weeks, but when in the middle of important operations the two weeks may be stretched.

Procedure

1 Hoist the transducer to its upper position.

2 Close the gate valve.

3 Perform a watertightness test.

Lubricating the drive chain

The drive chains must be kept lubricated to ensure smooth operation and to prevent corrosion.

Prerequisites

The grease must follow NLGI grade 2 and ISO VG 150.

Use Mobilux EP 2 or similar grease.

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Procedure

1 Switch off power to the system in the hoist control unit.

2 Inspect the drive chains looking for corrosion or dry areas.

If old grease has congealed or is badly contaminated with dirt etc, clean the effected areas using a scraper, solvents and cloths.

3 Inspect the sprockets for signs of wear and corrosion.

4 Clean off any corrosion with a chemical rust remover.

5 Check the tension in the drive chains, adjust the tension if necessary.

6 Lubricate the chain and sprockets using grease type BIRAL VG/HT or similar.

Apply using a suitable brush.

7 Wipe off excess grease and clean up any drips.

Lubricating the shaft sleeve

The sleeve contains several seals and these will wear as the transducer is lowered and raised.

Prerequisites

The grease must follow NLGI grade 2 and ISO VG 150.

Use Mobilux EP 2 or similar grease.

Context

If the shaft becomes dirty or the shaft sleeve runs dry, the seals will wear faster. This will in turn lead to leaks, and the seals will then need to be replaced.

• Keep the transducer shaft clean, and remove growth and dirt.

• Keep the transducer shaft oiled at all times.

• Keep the shaft sleeve filled with grease at all times.

Procedure

1 Switch off power to the system in the hoist control unit.

2 Clean the shaft sleeve, the filler and level/air vent screws and the surrounding area, removing all dirt and loose debris (paint flakes etc).

3 Remove the air vent screw.

Note

If the vent screw is not removed, the shaft seals can be damaged.

4 Fill the sleeve with grease, until the grease appears at the air vent hole.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

5 Replace the air vent screw.

6 Wipe off any excess grease.

7 Switch on the power to the system in the hoist control unit.

Hull unit inspection

The hull unit must be inspected every year, and before use, if it has not been used for an extended period.

Procedure

1 Switch off power to the system in the hoist control unit.

2 Check all power and signal cables for signs of damage or overheating.

3 Open all the junction boxes and check all cable terminations to ensure they are tight.

Close the boxes firmly when finished.

4 Check all cable glands to ensure they seal correctly

Refer to the Cable gland assembly procedure in the Cable layout and interconnections section if a gland is found to be loose.

5 Check around the hull unit, especially around the mounting flange for signs of water leakage.

If water is detected, find the leak. Tighten the bolts to close the leak, or refer to the appropriate procedure and replace the appropriate seals.

6 Check for signs of damage to the transducer shaft, for example scratches on the shaft surface, or sea growth. Clean if necessary.

If serious damage is detected, the shaft may need to be replaced. If in doubt, consult

Kongsberg Maritime or your dealer.

7 Check the motor gear box for signs of oil leaks.

8 Check the oil level in the gear box and fill if necessary.

9 Check the transducer shaft to ensure that it is correctly lubricated.

The shaft should be covered with a thin film of grease when it is raised. Refill the shaft sleeve when necessary.

10 Check the entire hull unit assembly for signs of corrosion.

If required, clean the corroded areas and apply the appropriate preservation mediums.

11 Check the tension of the drive chains and adjust if necessary.

12 Check that the upper and lower limit switches are securely and correctly located, and operate correctly.

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13 When the inspection is completed (other units may also need to be inspected), re-apply power to the system.

14 Hoist the transducer to its upper position.

15 Inspect the transducer.

See the procedures for cleaning the transducer and replacing a zinc anode.

If necessary, check that the system operates correctly by performing the system test procedure described in the Test and alignments procedures chapter.

Further requirements

Refer to spare parts list for overview of all available spare parts, and corrective maintenance for changing the parts.

Hoist control unit inspection

The hoist control unit must be inspected every year, and before use, if it has not been used for an extended period.

Procedure

1 Switch off all power to the system and remove the system fuses.

Power to the unit can be switched off using breaker F01. However this will not disconnect the mains voltage from the unit, so we recommend that you also remove the fuses in the ship's AC supply to the unit. Label the fuse panel to inform others that maintenance work is being carried out.

2 Check that all cable glands are correctly and tightly mounted into the unit.

3 Check that all cables are sealed.

4 Check that there is no tension on the cables.

5 Open the hoist control unit.

6 Check for signs of condensation or corrosion.

Dampness or corrosion indicates either that the equipment room is not properly ventilated and dry, or that the unit's door is not closed correctly. Investigate, and correct the fault.

7 Check that all cable terminations are tight, and that there is no indication of overheating.

If a cable termination is not tight, the bad connection will probably result in overheating, leading to more serious damage.

8 Check that all component units (relays, breakers, circuit boards etc.) are tight on their mounting rails.

9 Check that all manually operable switches and breakers operate smoothly.

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

10 On completion of the inspection (other units in the system may also need to be inspected) replace the system fuses and apply power to the system.

11 If necessary, check that the system operates correctly by performing the appropriate test procedures.

Further requirements

Refer to spare parts list for overview of all available spare parts, and corrective maintenance for changing the parts.

Checking and filling gear oil

Check the level of the gear oil in the hoist motor’s gear box every year.

Prerequisites

The gear oil must follow DIN CLP PG and ISO VG 680.

See the producer’s home page for more information about the S67 motor.

http://www.seweurodrive.com/

Procedure

1 Switch off power to the system in the hoist control unit.

2 Thoroughly clean the gearbox and the surrounding area, removing all dirt and loose debris (paint flakes etc).

3 Unscrew the filler cap A and the level screw B .

4 Fill the gearbox with oil to the level hole, if necessary.

5 Replace the level screw and the filler cap.

6 Wipe off any excess oil.

Preservation of units

Mounting flange

After welding completion all exposed surfaces must be painted with primer and topcoat, and antifouling where appropriate. Damaged paint must be repaired.

The mating surface of the flange unit must be protected with a wooden cover at all times till the gate valve is about to be installed.

Gate valve

Keep the gate valve in its transport protection until the start of installation. The mating surface of the gate valve must be protected with a wooden cover at all times till the gantry

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Interface specifications, page 75

is about to be installed. Make sure the limit switches are protected from mechanical damage as well as from dirt or liquids.

Gantry

Hoist control and transceiver unit

The units should be kept closed at all times when not operated. The units should be wrapped in heat and dust resistant material during any welding, grinding, painting or cleaning work nearby.

Cables

All installed cables to be securely routed in trays, protected from being stepped on or damaged by falling objects or particles.

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Technical specifications

Topics

Weights and outline dimensions, page 75

Power requirements, page 78

Environmental requirements, page 79

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Technical specifications

Interface specifications

The HiPAP Hull unit system will interface with peripheral systems and sensors using standard and/or proprietary datagram formats.

Supported datagram formats for motion information

• NMEA $**HDT

• NMEA $**VHW

• Yokogawa $**HRC

• SKR

• STL

• EM 3000

• $SPSXN,10

• $SPSXN,23

• IxSea Octans TAH ($PHOCT) R-P-H (UTC)

• IxSea Octans $PHTRO

• Ixsea Octans $PHLIN

The data rate should be at least 25 Hz, 100 Hz is recommended for attitude data.

Data input can be either serial line RS-232,RS-422 or Ethernet UDP.

Serial line speeds can be from 1200 baud up to 115200 baud, 1 or 2 stop bits, 7/8 bit data and parity none, even or odd.

Weights and outline dimensions

These weights and outline dimension characteristics summarize the physical properties of the HiPAP Hull unit High Precision Acoustic Positioning system.

Hull unit controller weight and outline dimensions

• Make and model : HiPAP Hull unit controller

• Outline dimensions :

– Depth : 236 mm

– Width : 380 mm

– Height : 629 mm

• Weight : 25 kg

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

HL 2180 weight and outline dimensions

• Make and model : HL 2180

• Outline dimensions :

– Height : 3.4 m

– Diameter : 670 mm

• Weight : 1150 kg (including transducer and transducer dock)

• Raise/lower travel : 2.2 m

HL 3770 weight and outline dimensions

• Make and model : HL 3770

• Outline dimensions :

– Height : 5 m

– Diameter : 670 mm

• Weight : 1330 kg (including transducer and transducer dock)

• Raise/lower travel : 3.8 m

HL 4570 weight and outline dimensions

• Make and model : HL 4570

• Outline dimensions :

– Height : 5.8 m

– Diameter : 670 mm

• Weight : 1430 kg (including transducer and transducer dock)

• Raise/lower travel : 4.6 m

HL 6120 weight and outline dimensions

• Make and model : HL 6120

• Outline dimensions :

– Height : 7.35 m

– Diameter : 670 mm

• Weight : 1600 kg (including transducer and transducer dock)

• Raise/lower travel : 6.1 m

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Technical specifications

Mounting flange weight and outline dimensions

• Make and model : DN 350

• Outline dimensions :

– Height : User selectable

– Inner diameter : 350 mm

– Outer diameter : 505 mm

• Weight : 140 kg

• Number of holes in the flange : 16 x M20

Mounting flange weight and outline dimensions

• Make and model : DN 500

• Outline dimensions :

– Height : User selectable

– Inner diameter : 500 mm

– Outer diameter : 670 mm

• Weight : 185 kg

• Number of holes in the flange : 20 x M24

Gate valve weight and outline dimensions

• Make and model : DN 350

• Outline dimensions :

– Height : 290 mm

– Inner diameter : 350 mm

– Outer diameter : 505 mm

– Width : 590 mm

• Weight : 225 kg

• Number and diameter of securing bolt holes : 16 x 22 mm

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Gate valve weight and outline dimensions

• Make and model : DN 500

• Outline dimensions :

– Height : 350 mm

– Inner diameter : 500 mm

– Outer diameter : 670 mm

– Width : 718 mm

• Weight : 370 kg

• Number and diameter of securing bolt holes : 20 x 26 mm

Power requirements

These power characteristics summarize the supply power requirements for the HiPAP

Hull unit High Precision Acoustic Positioning system.

Hull unit controller power specifications

• Make and model : Hull unit controller

• Voltage requirement : 230/440 VAC, 50 to 60 Hz 3-phase

• Power consumption : 750 — 1100 W, Depending on use

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Technical specifications

Environmental requirements

These environmental specifications summarize the temperature and humidity requirements for the HiPAP Hull unit High Precision Acoustic Positioning system.

Hull unit controller environmental requirements

• Make and model : Hull unit controller

• Operating temperature : 0 to +55 °C

• Storage temperature : -20 to 60 °C

• Degree of protection : IP54

• Operating humidity : 80 % relative

• Storage humidity : 90 % relative

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Drawing file

Topics

HiPAP General arrangement, page 81

Hull unit – Assembly drawing, page 82

Hull unit HL 3770, page 83

33473 Gate valve dimensions DN350, page 84

33414 Gate valve dimensions DN350, page 86

37357 Gate valve dimensions DN500, page 89

33498 Gate valve dimensions DN500, page 92

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HiPAP General arrangement

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

Hull unit – Assembly drawing

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Hull unit HL 3770

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33473 Gate valve dimensions DN350

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33414 Gate valve dimensions DN350

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37357 Gate valve dimensions DN500

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

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HiPAP 602/502/452/352/102 Hull unit Instruction manual

33498 Gate valve dimensions DN500

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