Kongsberg Maritime HiPAP 502/452/352/102 HiPAP hull units Instruction manual

Instruction Manual
HiPAP hull units
High Precision Acoustic Positioning
502/452/352/102 systems
HiPAP hull units
502/452/352/102 system
High Precision Acoustic Positioning
Instruction manual
Document history
Rev
B
Date
Written by
Checked by
Approved by
7. march 2016
AJ
HAA
JEF
New mounting flange and gate valve.
Copyright
© 2016 Kongsberg Maritime AS.
All rights reserved. The information contained in this document remains the sole
property of Kongsberg Maritime. No part of this document may be copied or
reproduced in any form or by any means, and the information contained within it is not
to be communicated to a third party, without the prior written consent of Kongsberg
Maritime.
HiPAP® is a registered trademark of Kongsberg Maritime AS in Norway and other
countries.
Disclaimer
Kongsberg Maritime endeavours to ensure that all information in this document is
correct and fairly stated, but does not accept liability for any errors or omission.
Warning
The equipment to which this manual applies must only be used for the purpose for
which it was designed. Improper use or maintenance may cause damage to the
equipment and/or injury to personnel. The user must be familiar with the contents of
the appropriate manuals before attempting to operate or work on the equipment.
Kongsberg Maritime disclaims any responsibility for damage or injury caused by
improper installation, use or maintenance of the equipment.
Support
All Kongsberg Maritime products:
Phone 24 hour: +47 33 03 24 07
E-mail: [email protected]
Instruction Manual
Additional manual
Hydraulic system for activation of the gate valve (option)
Separate manual supplied with the hydraulic system. This is not a Kongsberg Maritime
document.
Remarks
References
Further information about the HiPAP 502/452/352/102 system may be found in the
following manuals:

APOS for HiPAP Instruction manual

HiPAP 502/452/352/102 Instruction manual

HiPAP Cable plan and interconnections document
The reader
The installation information in this manual is intended for the design and installation
engineers at the yard performing the installation. The information is supplied as the
basis for the yard’s own installation drawings applicable to the vessel. On completion of
the installation, this chapter may be used for reference purposes during system
maintenance.
The maintenance information in this manual is intended to be used by a trained
maintenance technician or engineer, with experience of electronic and digital circuitry,
computers and electromechanical design. The level of information is based on
Kongsberg Maritime’s maintenance philosophy: The onboard technical personnel shall,
with the help of the documentation and the system’s built-in test functions, be able to
identify malfunctions, locate the fault, and replace major parts, modules and
components on the “Line Replaceable Unit” (LRU) level. Do not attempt to repair the
LRUs.
401497/B
I
HiPAP 502/452/352/102 hull units
High voltage safety warning
The voltages used to power this equipment are potentially lethal.
Even 110 volts can kill.
Whenever possible, the following precautionary measures
should be taken before any work is carried out inside the
equipment:
 Switch off all high-voltage power supplies.
 Check the operation of any door interlocks and any other
safety devices.
 Completely discharge all high-voltage capacitors.
It should be noted that interlocks and safety devices are
normally located only at regular access points, and high voltages
may be exposed during dismantling.
____________________________________________________________
Caution
Never work alone on high-voltage equipment! Refer to
general safety procedures.
____________________________________________________________
II
401497/B
Instruction Manual
Contents
1 ABOUT THIS MANUAL ........................................................................................9
Manual contents .................................................................................................................9
Abbreviations.....................................................................................................................9
Important information......................................................................................................10
2 SYSTEM DESCRIPTION .....................................................................................11
System overview..............................................................................................................11
HIPAP systems ................................................................................................................12
Hull units .........................................................................................................................12
Hoist motor and gearbox ......................................................................................... 13
Gantry ...................................................................................................................... 13
Shaft sleeve ............................................................................................................. 14
Transducer dock ...................................................................................................... 14
Mounting flange ...................................................................................................... 14
Transducer shaft ...................................................................................................... 15
Transducer ............................................................................................................... 15
Gate valve ................................................................................................................ 15
Hoist Control Unit ................................................................................................... 16
3 TECHNICAL SPECIFICATIONS .......................................................................17
Vessel speed ....................................................................................................................17
Packed dimensions and weights ......................................................................................18
Hull units .........................................................................................................................18
Gantry ..............................................................................................................................19
Mounting flange ..............................................................................................................20
Gate valve ........................................................................................................................20
Raise and lower motor .....................................................................................................21
Grease for shaft and chain ...............................................................................................21
Gear oil ............................................................................................................................22
Hoist Control Unit ...........................................................................................................22
Transducer units ..............................................................................................................24
4 INSTALLATION ...................................................................................................25
Supply conditions ............................................................................................................26
Equipment responsibility......................................................................................... 26
401497/B
III
HiPAP 502/452/352/102 hull units
Installation guidelines ............................................................................................. 26
Assistance from Kongsberg Maritime..................................................................... 26
Before you start ...............................................................................................................27
Precautions and requirements.................................................................................. 27
Sonar room requirements.................................................................................................27
Ventilation ............................................................................................................... 27
Bilge pump system .................................................................................................. 28
Torques ............................................................................................................................29
Standard tools ..................................................................................................................29
Special tools .....................................................................................................................29
Basic installation information ..........................................................................................30
Important information ............................................................................................. 30
Logistics .................................................................................................................. 31
Choice of location ................................................................................................... 31
Installation procedures .....................................................................................................32
Mounting flange installation ............................................................................................33
DN 700 mounting flange ......................................................................................... 33
DN 500 mounting flange ......................................................................................... 33
DN 350 mounting flange ......................................................................................... 34
Installation accuracy and tolerances ........................................................................ 34
Logistics .................................................................................................................. 34
References ............................................................................................................... 34
Important information ............................................................................................. 35
Installation procedure .............................................................................................. 35
Gate valve installation .....................................................................................................35
Location of the unit ................................................................................................. 36
Logistics .................................................................................................................. 36
O-ring ...................................................................................................................... 36
Procedure ................................................................................................................. 36
Gantry installation ...........................................................................................................38
Procedure ................................................................................................................. 38
Hoist motor mounting......................................................................................................39
Procedure ................................................................................................................. 39
Hull unit surface protection .............................................................................................40
IV
401497/B
Instruction Manual
Hoist Control Unit ...........................................................................................................40
Unit location ............................................................................................................ 42
Logistics .................................................................................................................. 42
References ............................................................................................................... 42
Procedure ................................................................................................................. 42
Preservation of HiPAP units ............................................................................................43
Mounting flange ...................................................................................................... 43
Gate valve ................................................................................................................ 43
Gantry ...................................................................................................................... 43
Hoist control and transceiver cabinets .................................................................... 44
Cables ...................................................................................................................... 44
5 CABLES ..................................................................................................................45
Cable gland assembly procedure .....................................................................................46
Securing and terminating the cables........................................................................ 47
Basic cabling requirements ..............................................................................................48
Cable planning .................................................................................................................51
Cable specifications................................................................................................. 51
Cable connections ................................................................................................... 52
Special cables .......................................................................................................... 52
Transducer to transceiver unit cables installation............................................................53
Cable information .................................................................................................... 53
Transducer cable connection ................................................................................... 53
Cables between the hull unit and the Hoist Control Unit ........................................ 54
6 OPERATION ..........................................................................................................55
Hoist control operation ....................................................................................................55
Important remote control information ..................................................................... 55
Lowering the hull unit ............................................................................................. 56
Raising the hull unit ................................................................................................ 57
Stopping the hull unit .............................................................................................. 57
Hoist control operation from Operator Station/APOS ....................................................57
Operating the Hoist Control from APOS ................................................................ 58
Gate Valve ............................................................................................................... 60
Manual operation of the hoist motor ...............................................................................62
401497/B
V
HiPAP 502/452/352/102 hull units
Procedure ................................................................................................................. 63
Gate valve operation ........................................................................................................63
7 MAINTENANCE ...................................................................................................64
Safety ...............................................................................................................................65
Before you start ...............................................................................................................66
Maintenance philosophy ..................................................................................................66
Maintenance schedule......................................................................................................67
Maintenance chart ................................................................................................... 67
Shaft sleeve and shaft, special attention ..........................................................................67
Watertightness test ...........................................................................................................68
Preventive maintenance ...................................................................................................69
Lubrication .............................................................................................................. 69
Hull unit inspection ................................................................................................. 70
Hoist Control Unit inspection ................................................................................. 72
Corrective maintenance ...................................................................................................73
Hoist motor, gear box lubrication ........................................................................... 74
Hoist motor replacement ......................................................................................... 75
Hoist motor, gear box replacement ......................................................................... 77
Drive chains lubrication .......................................................................................... 78
Drive chains tension ................................................................................................ 79
Drive chains replacement ........................................................................................ 81
Opening the transducer dock ................................................................................... 81
Lifting the hull unit ................................................................................................. 83
Transducer replacement .......................................................................................... 84
Transducer, marine growth removal ....................................................................... 86
Transducer cables replacement ............................................................................... 87
Shaft sleeve lubrication ........................................................................................... 91
Shaft sleeve disassembly ......................................................................................... 92
Zinc anode, inspection and replacement ................................................................. 95
Transducer shaft, guide rails adjustment ................................................................. 96
Limit switches replacement ..................................................................................... 97
Gate valve replacement ........................................................................................... 98
Hoist Control Unit ................................................................................................. 102
VI
401497/B
Instruction Manual
Test procedure ...............................................................................................................103
General checks ...................................................................................................... 103
System alignment .................................................................................................. 103
8 SPARE PARTS .....................................................................................................104
Codes used .....................................................................................................................104
Repair kit .......................................................................................................................105
Junction box kit for HiPAP hull unit .............................................................................105
Hull unit assembly spare parts .......................................................................................106
Chains ............................................................................................................................107
Transducer dock ............................................................................................................109
Transducer shaft sleeve .................................................................................................111
Transducer shaft sleeve-top ...........................................................................................114
Transducer .....................................................................................................................115
Hoist Control Unit .........................................................................................................116
9
LASER OPTION ..................................................................................................117
10
EQUIPMENT HANDLING.............................................................................118
Transportation ................................................................................................................118
Storage prior to installation or use ........................................................................ 119
Inspection .............................................................................................................. 121
Storage after unpacking .................................................................................................123
After use storage.................................................................................................... 124
Re-packing .....................................................................................................................126
ESD precautions ............................................................................................................126
Temperature protection..................................................................................................128
11
TEST AND ALIGNMENT PROCEDURES ..................................................129
Purpose ..........................................................................................................................129
Test certificates ..............................................................................................................129
Visual inspections ..........................................................................................................129
Test procedures introduction .........................................................................................130
Inspection of the hull unit ..............................................................................................131
Inspection of the Hoist Control Unit .............................................................................135
Cabling installation checks ............................................................................................137
Logistics ................................................................................................................ 137
Visual inspection of the cabling ............................................................................ 137
401497/B
VII
HiPAP 502/452/352/102 hull units
Cable connections and continuity ......................................................................... 137
Hull unit raise/lower manual checks .............................................................................139
Electrical check..............................................................................................................141
Remarks and signatures .................................................................................................145
12
DRAWING FILE ..............................................................................................146
Drawings ........................................................................................................................146
HiPAP hull unit typical arrangement, page 1 ........................................................ 147
HiPAP hull unit typical arrangement, page 2 ........................................................ 148
HiPAP hull unit mounting information ................................................................. 149
HiPAP HL 2180 .................................................................................................... 150
HiPAP HL 3770 page 1 ......................................................................................... 151
HiPAP HL 3770 page 2 ......................................................................................... 152
HiPAP HL 4570 .................................................................................................... 153
Hoist Control Unit – outline dimensions............................................................... 154
DN 700 mounting flange w/gate valve ................................................................. 155
DN 500 mounting flange w/gate valve ................................................................. 156
DN 350 mounting flange w/gate valve ................................................................. 157
EMC ground .......................................................................................................... 158
Minimum specifications ........................................................................................ 158
Transducer patch cable for all HiPAP systems ..................................................... 159
Transducer hull unit cable, for all HiPAP systems ............................................... 160
Hoist system, with hydraulic system for activating the gate valve via computer interconnection diagram ........................................................................................ 161
Hoist Control Unit – wiring diagram .................................................................... 162
13
CABLE PLAN AND INTERCONNECTIONS .............................................163
14
INDEX ...............................................................................................................164
VIII
401497/B
System description
1
ABOUT THIS MANUAL
This is the Instruction manual for the Kongsberg Maritime
HiPAP hull units 502/452/352/102 (named HiPAP hull unit in
rest of the manual).
Manual contents
The manual contains descriptions, specifications, procedures
and illustrations required to install and maintain the hull units.
The manual also defines the equipment responsibility, and
provides general information about preservation, packing and
storage of the units, and provides the Factory Acceptance tests
and the alignment procedures.

The operator station and transceiver units are described in the
HiPAP 502/452/352/102 Instruction Manual.
 The HiPAP Cable plan and interconnections are described in a
separate document.
The system is described down to the circuit board level, named
as Line Replaceable Units (LRUs), and block diagrams are used
to simplify the descriptions.
Abbreviations
Abbreviations used in this manual:
401497/B
DN
Diameter Nominal
FP
Fore Perpendicular
HCU
Hoist Control Unit
HiPAP
High Precision Acoustic Positioning
HPR
Hydroacoustic Position Reference
LBP
Length Between Perpendiculars
LBL
Long Base Line
LRU
Line Replaceable Unit
MTBF
Mean Time Between Failure
RCU
Remote Control Unit
TD
Transducer
9
HiPAP 502/452/352/102 hull units
Important information
____________________________________________________________
Note
When the system is not in use and the hull unit is fully raised,
you are advised to keep the gate valve closed.
Caution
10
Check the water depth before lowering the transducer
to avoid damaging the transducer.
401497/B
System description
2
SYSTEM DESCRIPTION
This chapter provides a brief description of the HiPAP hull unit
systems and a short description of each unit.
The purpose of the hull unit is to enable the transducer to be
lowered out through the vessel's hull to a depth below aerated
water and other sources of acoustic noise.
Topics

HiPAP systems on page 11

HiPAP hull unit systems description on page 12
Related topics

Vessel speed on page 17

HiPAP models - see HiPAP 502/452/352/102 Instruction
Manual
System overview
Figure 1 HiPAP hull unit system
401497/B
11
HiPAP 502/452/352/102 hull units
HIPAP systems
A complete specified HiPAP system depends on:
 Type of transceiver unit
 Type of hull unit
 Type of transducer
The following are available:
Transceiver unit
Hull unit
(available types)
Transducer
(available types)
Model x82
HL 2180
HiPAP 500 transducer
More information in the
HiPAP 502/452/352/102
Instruction manual
HL 3770
HiPAP 350 transducer
HL 4570
HiPAP 100 transducer
HL 6120
More information on page 22
(The numbers indicate the
hoist length in mm)
A complete HiPAP hull unit assembly also includes; cables
(patch cable and transducer cable), transducer dock, mounting
flange and gate valve.
Hull units
A HiPAP hull unit is a retractable hull unit system comprising
the following main parts:
 Hull unit systems overview - see illustration on page 11
 Hoist motor and gearbox
 Gantry
 Shaft sleeve
 Transducer dock with service hatch
 Transducer shaft
 Gate valve including:
 Positioning indicator (switch)
 Hydraulic system for activation of gate valve (option)
 Separate units:
 Hoist Control Unit
12
401497/B
System description
Topics

Hoist motor short description on page 13

Gearbox short description on page 13

Gantry short description on page 13

Shaft sleeve short description on page 14

Transducer dock short description on page 14

Mounting flange short description on page 14

Transducer shaft short description on page 15

Transducer short description on page 15

Gate valve short description on page 15

Hoist Control Unit detailed description on page 16
Related topics
Option:

Hydraulic system for activation of gate valve (option) → see
separate manual delivered with the gate valve.
Hoist motor and gearbox
The hoist motor and gearbox are mounted on the hoist platform.
This platform is at the top of the hull unit, mounted between the
tops of the gantry girders.
The transducer is raised and lowered by this electric motor.
A crank handle is provided, which can be attached to one end of
the motor shaft, to enable you to raise or lower the transducer
manually in the event of a power failure or for maintenance
purposes.
Gantry
The hull unit gantry consists of two vertical, parallel steel
girders, welded to a plate at their lower ends and with the hoist
motor platform bolted to their upper ends. The girders support
the transducer shaft when it is raised, and hold guide rails to
ensure the shaft is correctly aligned. The upper and lower limit
switches are mounted onto one of the girders.
401497/B
13
HiPAP 502/452/352/102 hull units
Shaft sleeve
The shaft sleeve is located in the bottom of the hull unit gantry.
The sleeve is bolted to the transducer dock, which in turn is to
be bolted to the gate valve. The shaft sleeve absorbs the forces
created by the water flow acting on the transducer and the
transducer shaft.
To prevent water leakage and to ensure smooth raising and
lowering of the transducer, the shaft sleeve is fitted with Lion
twin-set packing seals at its upper lower end. The space between
the seals is filled with grease to lubricate the seals and provide
extra watertight security.
When the sleeve is sufficiently filled, a thin film of grease will
be observable on the transducer shaft. Grease refilling and level
checking screws are located on the shaft sleeve.
____________________________________________________________
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.
____________________________________________________________
Transducer dock
The transducer dock consists of a steel box which holds the
transducer when the shaft is in the fully raised position. One side
of the transducer dock has a service hatch. If the transducer is
raised and the gate valve shut, the hatch may be opened to
expose the transducer for maintenance or exchange. Zinc anodes
are mounted inside the transducer dock.
Mounting flange
The mounting flange is welded to the vessels hull, and serves as
a base for the transducer raise/lower arrangement.
Note
The height of the mounting flange varies according to the
specific installation requirements of the vessel.
The mounting flange carries the gate valve which permits
onboard maintenance or replacement of the transducer.
14
401497/B
System description
Transducer shaft
The transducer shaft is a stainless steel tube which supports the
transducer at its lower end. It is supported at the top by guide
rails and the raise/lower drive chains within the hull unit gantry,
and it moves through the shaft sleeve. The signal cable between
the transducer and the transceiver unit runs up the inside of the
shaft, exiting at the top through sealing glands.
The transducer shaft is raised and lowered by drive chains,
driven via a gearbox by the motor mounted on the hoist
platform. The tension in the drive chain is adjusted using a
threaded bolt mechanism.
Transducer
The transducer is bolted to the lower end of the transducer shaft.
When the shaft is fully raised:
 The transducer is stored in the transducer dock.
 The gate valve can be closed to protect the transducer
completely from the open sea environment.
Gate valve
The gate valve shuts off the opening in the vessel’s hull when
the transducer is raised. The gate valve is supplied with a
position indicator.
A hydraulic system for automatic activation of the gate valve is
available as an option. This hydraulic system is described in a
separate document.
Gate valve position indicator
The purpose of the gate valve position indicator is to give a
feedback-indication of the gate valve position. The feedback is
done by use of switches.
The gate valve position indicator is mounted directly onto the
gate valve.
It consists of a slider sliding on a threaded spindle and two
switches operated by the slider.
Switch A - is operated when the gate valve is fully open.
Switch B - is operated when the gate valve is fully closed. In the
middle position no switch is operated.
401497/B
15
HiPAP 502/452/352/102 hull units
Note
The Hoist Control Unit uses the fully open indication (switch A)
only!
The Hoist Control Unit will not allow the hoist motor to move
the transducer shaft unless the gate valve is fully open.
Figure 2 Gate valve with position indicator
Hoist Control Unit
The Hoist Control Unit (HCU) is a standard unit used with all
types of hull units. This unit is a steel cabinet with hinged front
door.
The unit is designed to be mounted on a bulkhead close to the
hull unit gantry. For safety reasons there must be a clear line of
sight from the HCU to the hull unit.
16
401497/B
Installation
3
TECHNICAL SPECIFICATIONS
This chapter gives the technical specifications of the HiPAP hull
units.
Topics

Vessel speed on page 17

Packed dimensions and weights on page 17

Hull units outline dimensions on page 18

Gantry on page 19

Mounting flange on page 20

Gate valve on page 20

Raise and lower motor on page 21

Grease on page 21

Gear oil on page 22

Hoist Control Unit with Ethernet interface on page 22

Transducer units on page 22
Vessel speed
____________________________________________________________
Caution
Once the transducer is lowered, the depth of water
under the vessel must be monitored closely.
The max vessel speed - when the transducer is in the
401497/B
17
HiPAP 502/452/352/102 hull units
lowered position:
Hull unit type
Max vessel speed when the
transducer is in lowered
position
HL 2180
10 knots
HL 3770 (standard)
10 knots
HL 4570
8 knots
HL 6120
6 knots
____________________________________________________________
Packed dimensions and weights
____________________________________________________________
Note
All packed dimensions and weights are approximate and will
depend on the packing materials available at the time of
shipment.
Hull unit packing material: Wooden crate weight: 400 kg
____________________________________________________________
Typical delivery of HiPAP 500 with 3770 HL:
Unit
Length
Width
Height
Weight
Net
weight
Volume
Hull unit
620 cm
82 cm
96 cm
1500 kg
1100 kg
4.88 m3
Transceiver 92 cm
87 cm
77 cm
136 kg
85 kg
0.62 m3
Transceiver 47 cm
fibre kit
32 cm
23 cm
3.5 kg
2.80 kg
0.03 m3
Hull units
Topics
18

HiPAP HL 2180 - dimensions on page 150

HiPAP HL 3770 - dimensions on page 151

HiPAP HL 4570 - dimensions on page 152
401497/B
Installation
The following specifications are common for all
HiPAP hull units:
Protection
Degree of protection:
IP 54
Power supply
Voltage:
230/440 Vac 3-phase
Frequency:
50-60 Hz
1100 W
Power consumption max:
0° C to +55° C
Operating temperature:
Environment conditions
Storage:
- 20° C to +65° C
Storage/operating humidity:
90% / 80% relative
Gantry
An opening through the deck is required for installation or
removal of a hull unit.
 With transducer dock:
diameter 800 mm
 Without transducer dock: diameter 700 mm
Specifications
HL 2180
Gantry
HL 3770
Gantry
HL 4570
Gantry
HL 2180
HL 3770
HL 4570
3.4 m
5m
5.8 m
Max diameter (bottom flange):
670 mm
670 mm
670 mm
Weight including transducer and
transducer dock:
1150 kg
1330 kg
2.2 m
3.8 m
Gantry type:
Height (above dock):
Distance of raise/lower travel (approx):
401497/B
1430 kg
4.6 m
19
HiPAP 502/452/352/102 hull units
Mounting flange
Specifications
DN 700 mm
mounting flange
DN 500 mm
mounting flange
DN 350 mm
mounting flange
Type:
DN 700
DN 500
DN 350
Standard height:
As low as possible
As low as possible
As low as possible
Optional height:
Specified by
customer
Specified by
customer
Specified
customer
Diameter
Internal/Flange:
700 mm/895 mm
500 mm / 670 mm
350 mm / 505 mm
Wall thickness:
25 mm
20 mm
20 mm
Weight (standard):
Approx. 320 kg
Approx. 185 kg
Approx. 140 kg
Securing bolt holes:
Quantity: 24
Diameter: M27
Quantity: 20
Diameter: M24
Quantity: 16
Diameter: M20
See also drawing:
on page 155
on page 156
on page 157
by
Gate valve
Certificates - DNV certifications are standard, others on request.
Specifications
DN 700 gate
valve
DN 500 gate
valve
DN 350 gate
valve
Part no:
404542
HDV-088347
HDV-051336
Type:
DN 700
DN 500
DN 350
Height:
430 mm
350 mm
290 mm
Weight:
780 kg
500 kg
225 kg
Material case (body):
670 mm Nodular
cast iron
670 mm Nodular
cast iron
670 mm Nodular
cast iron
Material gate (wedge):
Nodular cast iron
Nodular cast iron
Nodular cast iron
Material seat rings:
Bronze
Bronze
Bronze
Length (from centre):
1560 mm
1335 mm
940 mm
Diameter
Internal/Flange:
700 mm/895 mm
500 mm / 670 mm
350 mm / 505 mm
20
401497/B
Installation
Specifications
Securing bolt holes:
See also drawing:
DN 700 gate
valve
Quantity: 24
Diameter: Ø30
on page 155
DN 500 gate
valve
DN 350 gate
valve
Quantity: 20
Quantity: 16
Diameter: 26 mm
Diameter: 22 mm
on page 156
on page 157
Raise and lower motor
Motor type:
SEW EURODRIVE S67
DT80N4BM/HF
Degree of protection:
Input voltage:
Phase:
Rated power:
Speed:
Timken OK Load, ASTM D 2509
Operating temperature:
IP 54
230/440 Vac
3 Phase
750 W
1500 RPM
lb: 40
0°C to +70°C
Environment conditions
Storage:
Storage/operating humidity:
- 20°C to +65°C
90% / 80% relative
Grease for shaft and chain
Exxon Mobil Mobilux EP2 (or equivalent)
Mobilux EP 2 is a high performance, general-purpose industrialtype grease. This lithium hydroxystearate based grease is
formulated to provide extra protection against wear, rusting and
water washout. It is NLGI Grade 2 with a base oil viscosity of
ISO VG 150.
Typical properties
NLGI Grade:
Thickener Type:
Colour, Visual:
401497/B
2
Lithium
Brown
Penetration, Worked, 25 ºC, ASTM D 217:
280
Viscosity of Oil, ASTM D 445 c St @ 40 ºC:
160
21
HiPAP 502/452/352/102 hull units
Timken OK Load, ASTM D 2509:
1b: 40
4-Ball Wear, ASTM D 2266, Scar:
0.4 mm
4-Ball Weld Load, ASTM D 2509:
250 Kg
Dropping Point, D 2265:
190ºC
Rust Protection, ASTM D 6138, distilled water:
0-0
Equivalents
Possible equivalents – use grease with approximate the same
properties as specified above.
Gear oil
Mobilgear 636 (ISO VG 680) (Shell Tellius oils 32S)
(or equivalent)
Typical properties
Viscosity cSt/100 C:
37.47
Viscosity cSt/40 C:
680
Viscosity index:
90
Specific gravity at/15 C:
0.920
Flashpoint COC, C, min:
250
AGMA No 250.03:
8-EP
Point of solidification, max:
-15C
Rust ASTMD 665A/B:
pass
Four ball Weld Point, N:
3150
Equivalents
Possible equivalents – use oil with approximate the same
properties as specified above.
Hoist Control Unit
The Hoist Control Unit is normally delivered with vibration
damping devices.
22
401497/B
Installation
____________________________________________________________
Note
The unit must be kept in an operational environment with the
room temperature and humidity within the specified limits, and
in a corrosive, salt and dust-free atmosphere.
____________________________________________________________
Dimensions

Outline dimensions - see drawing in the Drawing file chapter
from page 146.
Protection
Degree of protection:
IP 54
Power
Voltage:
Frequency:
Power consumption:
Operating temperature:
230 Vac / 440 Vac, 3 phase 3
phase
50 – 60 Hz
750 – 1100 W
depending on application
0°C to +55°C
____________________________________________________________
Note
The power supply to the Hoist Control Unit must be kept within
+10% of the unit’s nominal voltage. The maximum transient
voltage variations on the main switchboard’s bus-bars which
could occur (except under fault conditions), are not to exceed 15% to +20% of the nominal voltage.
____________________________________________________________
Environment conditions
Storage:
Storage / operating humidity:
401497/B
- 20°C to +65°C
90% / 80% relative
23
HiPAP 502/452/352/102 hull units
Figure 3 Hoist Control Unit – maintenance access
Transducer units
 Weight, see the Drawing file chapter from page 146.
24
401497/B
Installation
4
INSTALLATION
This chapter provides the descriptions and drawing references
required to install the HiPAP hull units.
The guidelines for installation presented in this manual must be
regarded as a base for detailed plans prepared by the installation
yard.
____________________________________________________________
Note
Detailed mechanical drawings for the installation of the hull
unit must be created and provided by the yard for the specific
vessel. All drawings must be approved by local maritime
authorities prior to the start of the installation.
____________________________________________________________
Warning
The installation instructions given in this manual
must be followed. Failure to do so may render the
guarantee void.
____________________________________________________________
Warning
Kongsberg Maritime AS accepts no responsibility
for any damage or injury to the system, ship or
personnel caused by drawings, instructions and
procedures not prepared by Kongsberg Maritime.
____________________________________________________________
Topics

Supply conditions on page 26

Before you start on page 27

Sonar room requirements on page 27

Torque on page 29

Tools on page 29

Basic installation information on page 30

Installation procedures on page 32
Related topics
401497/B

Cables on page 45

Drawings in the Drawing file chapter from page 146
25
HiPAP 502/452/352/102 hull units
Supply conditions
Equipment responsibility
Upon receipt of the equipment the system owner or installation
yard automatically becomes fully responsible for the equipment,
unless otherwise stated in the contract. This responsibility
covers the storage period before installation, the actual
installation, commissioning, and the period between the
completion of the commissioning and the acceptance of the
equipment by the end user (normally the owner of the vessel or
platform into which the equipment is to be installed).

Reception, unpacking and storage. A separate chapter,
Equipment handling is provided for this information - on page
117.
Installation guidelines
Unless otherwise stated, the installation yard is responsible for
the installation of the entire HiPAP system. In addition, the yard
is responsible for providing and connecting all cables. The
actual installation and cable laying must comply with the
vessel’s classification rules and the recommendations given in
this manual.
Assistance from Kongsberg Maritime
Kongsberg Maritime AS may assist during the installation if
specified in the contract or requested by the installation yard or
customer. Kongsberg Maritime AS may also assist with
installation drawings. All such assistance is charged to the
customer at the current rates.
If required during a contractual test period, the yard must
provide assistance necessary for the rapid and efficient
completion of the work even when the work is to be performed
outside normal working hours. This requirement includes
assistance from subcontractors when applicable. Excessive
waiting time resulting from delays caused by the yard will be
charged to the yard.
26
401497/B
Installation
Before you start
Precautions and requirements
Before you start the installation, you must take the following
actions:
 Collect the required documentation and read the applicable
procedures before commencing work.
 Collect the required tools. Normally only a standard tool set
will be required. If special tools are necessary to perform a
task, the procedure will list those required.
 Ensure that all power is switched off to the system, and
remove the fuses. If power is required to perform a task, the
procedure will state so.
 Label the on / off switches, circuit breakers and fuses with
notes clearly stating that work is being carried out on the
system.
Sonar room requirements
The sonar room should be large enough to house all the system
units, with enough space to allow maintenance to be performed
efficiently. The maintenance engineer should be able to have all
the cabinet doors open without undue restriction to his/her
movements.
The room should be easily accessible, via a hatch or door. It
would be advantageous if the entry was large enough to allow
installation and removal of the equipment contained in the
compartment without the requirement for disassembly.
Lights must be permanently installed in the sonar room. A voice
intercom terminal, with connections to the operator station and
the bridge, is highly recommended.
Ventilation
The room must be connected to the vessel’s ventilation system
to ensure a supply of cooling air to the units. It is recommended
that the temperature should be between +5 and +40 °C, and
relative humidity should not exceed 80%. The MTBF (Mean
Time Between Failure) will decrease if these limits are
exceeded.
401497/B
27
HiPAP 502/452/352/102 hull units
If a ventilation system is not available, install two 3” pipes from
the equipment 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 should
be located below the pipes to collect any condensation which
may form. To ensure the best possible ventilation, the air outlet
on deck should be located four metres higher than the air inlet,
and goose-necks or hats should be mounted on the tubes to
prevent the ingress of rain or sea water.
Bilge pump system
The room must be serviced by a bilge pump system. If it is
impractical to connect the room to the vessel’s bilge pump, a
separate pump must be installed to drain the room in the event
of water ingress.
28
401497/B
Installation
Torques
All the nuts and bolts used in the system must be tightened to
their recommended torques to prevent leaks or damage to the
threads. The recommendation is for threads lubricated with antiseize lubricant. The recommended tightening torques for the
various sizes of threads is as follows:
Nut/bolt torques
Thread
size (mm)
Torque
(Nm)
M6
7 Nm
M8
17 Nm
M10
33 Nm
M12
57 Nm
M16
140 Nm
M20
273 Nm
M24
472 Nm
Standard tools
A standard mechanical tool set will be required for:
 Perform the installation, removal and replacement of
modules and parts described in this manual.
 Perform the majority of the maintenance described in this
manual.
A standard electrical tool set may be required to perform repairs
to cables etc.
In addition, the normal heavy tools designed for installation
work is required.
The following expendables are recommended:
 Isolating plastic tape
 Solders
 Wire straps in different sizes
Special tools
If special tools are required for a particular procedure, they will
be listed at the beginning of that procedure.
401497/B
29
HiPAP 502/452/352/102 hull units
Basic installation information
The installation of the hull unit and associated units includes the
following:
 Selection of the hull unit location.
 Installation of the hull unit. This includes:
 Installation of the mounting flange at the site chosen for
the hull unit.
 Installation of the gate valve.
 Mounting of the hull unit assembly (transducer dock,
shaft sleeve, gantry and transducer).




 Mounting of the hoist motor.
Mounting of the hoist control and remote control units.
Control signal and power supply cabling.
Hydraulic system for activation of gate valve (option) - see
separate documentation delivered with the system.
Test and alignment procedures.
Topics

Important information on page 30

Logistics on page 31

Choice of location on page 31

Installation procedures on page 32
Related topics

Cable layout and interconnections on page 40

Test and alignments procedures from page 129

Drawing in the Drawing file chapter from page 146
Important information



30
Water inlets and protruding elements that might cause
turbulence around the transducer, must not be located
forward of the flange.
Reinforcing plates and braces must be added to the vessel
where the hull unit installation might weaken the hull
construction.
The Hoist Control Unit must be mounted on the bulkhead in
the vicinity of the hull unit. The Hoist Control Unit controls
401497/B
Installation
the hull unit hoisting and lowering operations locally,
therefore for safety reasons it should be mounted with a free
line of sight to the hull unit.
Logistics
Safety - Refer to the local general safety procedures.
The parts of the hull unit are heavy. Use only suitable and
properly certified lifting apparatus to move the units.
Personnel - Trained mechanical fitters/welders and electricians.
Vessel location - The vessel must be in a dry dock during the
installation of the mounting flange and gate valve. The hull unit
gantry can be installed while the vessel is afloat if necessary.
Special tools - Certified lifting apparatus suitable for the various
parts. Cutting/welding equipment.
Choice of location
Caution
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 larger DN700 gate valve will need a 1000 mm
diameter hole.
 The compartment should also be connected to the ship’s
ventilation system. In tropical regions an air dehumidifier is
401497/B
31
HiPAP 502/452/352/102 hull units

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.
 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.

Air vent cock, see figure on page 109
Installation procedures
The installation must be carried out according to the
arrangement drawings designed specifically for the vessel.

See also drawings in the Drawing file chapter from page 146
Topics
32

Mounting flange installation on page 33

Gate valve installation on page 35

Gantry installation on page 38

Hoist motor mounting on page 39

Hull unit surface protection on page 40
401497/B
Installation

Hoist Control Unit with Ethernet interface on page 40
Mounting flange installation
The mounting flange is welded into a hole cut in the vessel’s
bottom and provides a secure base for the hull unit assembly.
 The HiPAP 500/450/100 transducer (the complete hull unit)
must be mounted on the DN 500 mounting flange.
 The HiPAP 350 transducer (the complete hull unit) can be
mounted on the DN 500 or a DN 350 mounting flange.
____________________________________________________________
Note
The total height of the mounting flange will depend on the
Note
requirements for the specific installation. The standard height is
DN 500 = 600 mm/DN 350 = 200 mm, though other sizes can be
provided on request.
Cut the mounting flange to the shortest possible length for
installation.
DN 700 mounting flange
The DN 700 mounting flange comprises a steel cylinder, topped
by a flange ring.
The flange ring contains 24 equally spaced holes, each bored to
receive M27 bolts. The holes are on a pitch circle diameter of
840 mm, with a pitch of 15°.
 See drawing in the Drawing file chapter from page 155.
The flange welded around the top of the cylinder enables a gate
valve to be bolted onto the top.
DN 500 mounting flange
The DN 500 mounting flange comprises a steel cylinder, topped
by a flange ring.
The flange ring contains 20 equally spaced holes, each bored
and tapped to receive M24 studs. The holes are on a pitch circle
diameter of 620 mm, with a pitch of 18°.
 See drawing in the Drawing file chapter from page 146.
The flange welded around the top of the cylinder enables a gate
valve to be bolted onto the top.
401497/B
33
HiPAP 502/452/352/102 hull units
DN 350 mounting flange
The DN 350 mounting flange comprises a steel cylinder, topped
by a flange ring.
The flange ring contains 16 equally spaced holes, each bored
and tapped to receive M20 studs. The holes are on a pitch circle
diameter of 460 mm, with a pitch of 22.5°.
 See drawing in the Drawing file chapter from page 146.
The flange welded around the top of the cylinder enables a gate
valve to be bolted onto the top.
Installation accuracy and tolerances
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 (3) 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.
Logistics
Safety - Refer to the general safety procedures. Note that the
mounting flange is heavy. Use only properly certified lifting
apparatus to move the unit.
Personnel - Minimum 3 trained mechanical fitters / welders.
Vessel location - The vessel must be in a dry dock during the
installation of the mounting flange.
Special tools - Certified lifting apparatus. Cutting and welding
equipment.
References
Drawings
- DN 350 mounting flange with gate valve on page 157
- DN 500 mounting flange with gate valve on page 156
34
401497/B
Installation
- DN 700 mounting flange with gate valve on page 155
Important information
____________________________________________________________
Note
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.
____________________________________________________________
Warning
The security of the welding is critical to the safety
of the vessel. Welding must only be carried out by
a certified welder, and the installation must be
approved by the local classification authorities.
____________________________________________________________
Installation procedure
1
Decide the location of the hull unit.
2
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 yard.
3
Orientate the mounting flange correctly, and then weld it
into position.
4
Check the flange surface to ensure that it is level,
undamaged and clean, and cover it for protection.
5
Brace the flange to the hull plating and the surrounding
hull frames by welding on several strengthening plates.
- The exact dimensions of the plates must be
determined by the yard.
Gate valve installation


401497/B
The HiPAP 500/450/100 hull unit fits on a DN 500 or a DN
700 gate valve.
The HiPAP 350 hull unit fits either the DN 350 or the DN
500 gate valve. As a standard, Kongsberg Maritime
35
HiPAP 502/452/352/102 hull units
recommend to use a DN 500 gate valve. Details of both are
given here.
Location of the unit
The gate valve is installed between the mounting flange and the
hull unit transducer dock.
Logistics
Safety - Refer to the general safety procedures. Note that the
gate valve is heavy. Use only properly certified lifting apparatus
to move the unit.
Personnel - Minimum 3 trained mechanical fitters.
Vessel location - The vessel must be in a dry dock during the
installation of the gate valve.
Special tools - Certified lifting apparatus.
References
Drawings:
- DN 350 mounting flange with gate valve on page 157
- DN 500 mounting flange with gate valve on page 156
- DN 700 mounting flange with gate valve on page 155
O-ring
A standard delivery includes one O-ring.
 The O-ring is used to seal the connection between the gate
valve and the mounting flange.
Procedure
The procedure assumes a standard DN500 gate valve and
mounting flange.
See also the drawing on page 155
1
36
Ensure that:
- the mounting flange has been installed correctly
- the installation has been inspected
- any offsets are within tolerance.
- the mating surface is clean and undamaged.
401497/B
Installation
2
Manoeuvre the gate valve down into the hull unit
compartment, leaving about 15 mm.
- Take great care not to damage the mating surfaces of
the valve.
- Make sure that the end switches are facing upwards.
- Protect the end switches from damage.
3
Remove the protective cover from the mating surface on
the mounting flange.
4
Check to ensure the mating surface of the flange is clean
and undamaged.
5
Orientate the gate valve so that the wheel points in the
desired direction.
6
Make sure there are no holes alongships or athwartships.
See the drawing on page 155.
7
Wipe a thin film of silicone grease on the O-ring and place
it on the mounting flange.
8
Attach the nuts and split washers while the gate valve is
still suspended.
9
Check to ensure the mating surface on the valve is clean
and undamaged.
Lubricate the threads with anti-seize lubricant as CRC,
Loctite or Molykote.
10
Lower the valve carefully onto the mounting flange while
tightening the nuts.
11
Check to ensure the valve is orientated and aligned
correctly.
12
Disconnect and remove the lifting apparatus.
13
Tighten the nuts to torque 472 Nm.
14
Some of the positions have very limited space as indicated
on the drawing on page 155.
Alternative:
401497/B
15
If there is no room for split washer use Loctite 270 or
similar.
16
M24 holes may be drilled to Ø26. Replace the studs with
cylinder head bolt M24x100 DIN933, A4-70 ISO 3506-1
(min).
17
Fasten to a torque of 472 Nm.
37
HiPAP 502/452/352/102 hull units
Gantry installation
The flange at the bottom is to be mated to the gate valve flange.
The mating surface of the hull unit must be protected with
wooden covers at all times until the moment of installation.
The hull unit is normally transported in a wooden crate.
Logistics
Safety - Refer to the general safety procedures. Note that the
parts of the hull unit are heavy. Use only suitable and properly
certified lifting apparatus to move the units.
Personnel - Four trained mechanical/electrical fitters.
Vessel location - The vessel must be in a dry dock during the
installation of the mounting flange and gate valve. The hull unit
gantry can be installed while the vessel is afloat if necessary.
Special tools - Two certified lifting apparatus, each with the
capacity to support the entire hull unit (approximately 1.5 tonnes
depending on hull unit model).
References
Drawings - hull units, outline dimensions drawing, in the
Drawing file chapter from page 146.
Procedure
38
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.
401497/B
Installation
7
Remove the protective cover from transducer dock and
gate valve flanges, and check that the mating surfaces are
clean and undamaged.
8
Wipe a film of grease - (see page 21) in its groove, and
position the O-ring seal.
9
Carefully lower the gantry 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
(ensuring 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 a final torque - see table on page 29.
____________________________________________________________
Note
The gantry will be subjected to large forces as the vessel moves
through the water, and as it pitches and rolls. The gantry must
therefore 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
drawing.
____________________________________________________________
13
Ensure that no units or protrusions will obstruct the
vertical movement of the hull unit or the transducer
cables.
Hoist motor mounting
The hull unit is delivered with the motor dismounted. It must
therefore be fitted during the installation. It is recommended to
fit the motor after the hull unit has been installed in the vessel.
Procedure
401497/B
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.
39
HiPAP 502/452/352/102 hull units
4
Cut away the plastic vent plug on the oil filler plug to
allow the gearbox to “breathe”.
Hull unit surface protection
The hull unit must be protected against corrosion, especially
those parts which are open to the sea. The HiPAP hull unit has
two zinc anodes mounted on the shaft sleeve to protect against
galvanic corrosion. However, all exposed surfaces must be
painted with a primer and topcoat/antifouling paint.
Caution
NEVER paint transducer face, shaft or zinc anodes. Do
not paint the sealing surfaces in the gate valve, this will
cause leakage.
____________________________________________________________
Logistics
Safety - Refer to the general safety procedures. Switch off all
power to the hull unit before commencing the work.
Personnel - Painter.
Vessel location - The vessel must be in a dry dock if parts open
to the sea are to be painted. Dry parts within the vessel’s hull
can be painted at any time.
Special tools - Painting tools and primer, undercoat, topcoat,
anti-fouling paint as for remainder of vessel’s hull.
Hoist Control Unit
This section describes the installation of the Hoist Control Unit
(HCU).
Internal layout
The Hoist Control Unit (HCU) contains the electronic circuitry
and relays required to raise and lower the hull unit.
A rotary control switch (S1) within the cabinet enables the
operator/maintenance engineer to raise or lower the hull unit
locally.
An additional position on the switch changes control of the hull
unit to a remote control via Ethernet from the computer.
The units and components are laid out as shown in the following
figure.
40
401497/B
Installation
Relay
(K03)
Relay
(K02)
Power
supply
Vibration
damper
NB!
Automatic
circuit breaker
(F01)
Always check the Gate Valve is
fully open before lowering the hull
unit.

Motor protection
relay (F02)
See also outline drawing on
page 154
Digital
input
ADAM
- 6066
Remote
switch
(S1)
Terminal
block
HCTB1
Absorber
bracket
(Cd31223)
Figure 4 Hoist Control Unit with Ethernet interface - internal layout
Connections
All cables to the HCU enter the unit through cable gland located
in the base of the unit.
The connections are as follows:
 Controlled mains supply to hull unit raise/lower motor.
 Ethernet cable from Remote Control Unit to Transceiver unit
or computer (remote control).
 6-core signal cable from the hull unit
(limit switches etc.).
 2 cables (4-core) to Gate Valve Open / Closed switch
(if mounted).
The connections for the power and interface cables to the Hoist
Control Unit are described here.
Installation of cables

401497/B
Cable layout and interconnection chapter from page 40
41
HiPAP 502/452/352/102 hull units
The HCU is fitted with four mounting lugs. Holes can be drilled
in the bulkhead and bolts, nuts and washers used to secure the
unit, or studs can be welded to the bulkhead and the unit secured
to these.
Unit location
The HCU will normally be mounted in the close vicinity of the
hull unit.
 The lengths of the system cables do not place any practical
restrictions on the distance between the HCU and the hull
unit into which it is connected.
 The HCU is designed to be mounted on a bulkhead, but can
be mounted directly onto the hull unit gantry if necessary.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Minimum 2 trained mechanical / electrical workers
Vessel location - No special requirements.
Special tools - None
References
Drawings:

Drawings in the Drawing file chapter from page 146
Procedure
____________________________________________________________
Caution
For safety reasons, the Hoist Control Unit must be
mounted such that the operator has a direct and
unimpeded line of sight from the cabinet to the hull
unit.
____________________________________________________________
42
1
Select an appropriate location for the unit.
2
Check on the other side of the bulkhead to ensure there
will be no “surprises” when the holes are bored or welding
is performed.
3
Bore the holes to fit M8 bolts, or weld four M8 x 12 mm
long studs to the appropriate positions on the bulkhead.
4
Lift the cabinet against the bulkhead and align the
mounting holes/studs.
401497/B
Installation
5
Locate the bolts/studs through the holes, place washers
onto the threads, then screw nuts onto them.
6
Ensure the cabinet is positioned correctly, then tighten the
nuts to final torque – see table on page 29.
7
Referring to the relevant cabling documentation and
interconnection diagrams, connect in the cables.
8
Once all the cables have been installed and the installation
has been checked, remove all “foreign” matter from the
cabinet and shut the door.
Preservation of HiPAP units
This procedure helps preservation of HiPAP units during
commissioning and maintenance work on board.
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.
401497/B
43
HiPAP 502/452/352/102 hull units
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.
Hoist control and transceiver cabinets
Cabinets to be kept closed at all times when not operated.
Cabinets to 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.
44
401497/B
Cables
5
CABLES
This chapter provides general installation requirements for
cables and explains how to perform the interconnections
between those units.
Note
All cable connections must be made in accordance with the
guidelines laid down by the vessel’s classification society.
If no such guidelines exist, Kongsberg Maritime recommends
that the Det Norske Veritas (DNV) Report No. 80-P008,
“Guidelines for Installation and Proposal for Test of
Equipment” be used as a guide.

See Cable plan and interconnections document 325840
(separate document) for more information.
Topics

Cable gland assembly procedure on page 46

Basic cable requirements on page 48

Cable plan on page 51

Transducer to transceiver unit cables installation on page 53
Related topics
401497/B

Cable plan and interconnections on page 163

Drawings in the Drawing file chapter from page 146
45
HiPAP 502/452/352/102 hull units
Cable gland assembly procedure
Cable glands are used whenever a cable passes through a watertight bulkhead or into a cabinet, to seal the opening through
which the cable passes and to protect the cable from abrasion on
the edges of the hole. Follow the guidelines in this chapter when
installing cables through cable glands.
____________________________________________________________
Note
There are many different types of cable gland on the market.
This procedure describes the types used (now and previously) as
standard in the units manufactured by Kongsberg Maritime. The
cable glands are not supplied with the system.
____________________________________________________________
Even though the cabinets from Kongsberg Maritime may be
prepared for specific types, the installation yard will be
responsible for selecting cable gland types and installing them.
General procedure
1
Ensure all the cables to be connected are completely
isolated from any power sources.
- This is done by:
Switch off and remove the supply fuses from any units
or systems into which the cables are already
connected.
2
Select the cable to be connected into the cabinet, and
select the cable gland through which the cable is to pass.
____________________________________________________________
Note
A minimum of 5 cm (recommended 5 - 10 cm) of slack cable
must be allowed, both inside and outside the cabinet, when
installing cables. This is to allow for vibration damping,
maintenance and measurement errors. Always double-check
your measurements before taking any irreversible actions.
____________________________________________________________
3
Depending on whether the cable has already been installed
in conduits, either
a (installed) measure the maximum length of cable
required to reach from the final cable clip outside the
cabinet to the terminal blocks inside the cabinet, add 20
cm, then remove the excess cable, or:
b (loose cable) measure the maximum length of wire
required to reach from the cable gland to the terminal
46
401497/B
Cables
blocks inside the cabinet, add 20 cm. and mark the
cable.
____________________________________________________________
Note
The cable’s outer insulation will extend into the cable gland to a
point approximately 5 mm outside the outer surface of the
cabinet wall into which the cable gland is secured.
____________________________________________________________
4
Take care not to damage the screening. Carefully remove
the outer insulation from the required cable length.
5
Leave an appropriate length of the screen exposed from
the insulation, and cut off the remainder.
Securing and terminating the cables
401497/B
1
Refer to the wiring diagram and ensure that there is 5 to
10 cm slack cable inside the cabinet, - then prepare and
connect the cable cores to the appropriate terminals within
the cabinet.
2
Secure the cable within the cabinet using cable clips.
3
Check the terminal connections against the wiring diagram
to ensure they are correct.
47
HiPAP 502/452/352/102 hull units
Follow the same procedure for all the cables and cable glands.
Once all the cables have been fitted:
4
Check the cabinet to ensure all tools and rubbish are
removed, before you close the cabinet door.
Once all the cables have been fitted and checked:
Caution
Caution
Take the appropriate safety measures, then replace the
fuses and apply power to the system.
Perform a system test to ensure the installation has
been conducted successfully.
Basic cabling requirements
Cable trays
All permanently installed cables associated with the system
must be supported and protected along their entire lengths using
conduits and/or cable trays. The only exception to this rule is
over the final short distance (max. 0.5 m) as the cables run into
the cabinets/units to which they are connected. These short
service loops are to allow the cabinets to move on their shock
mounts, and to allow maintenance and repair.
 Wherever possible, cable trays must be straight, accessible
and placed so as to avoid possible contamination by
condensation and dripping liquids (oil, etc.). They must be
installed away from sources of heat, and must be protected
against physical damage. Suitable shields must be provided
where cables are installed in the vicinity of heat sources.
 Unless it is absolutely unavoidable, cables should not be
installed across the vessel’s expansion joints. If the situation
is unavoidable, a loop of cable having a length proportional
to the possible expansion of the joint must be provided. The
minimum internal radius of the loop must be at least twelve
times the external diameter of the cable.
 Where a service requires duplicate supply lines, the cables
must follow separate paths through the vessel whenever
possible.
 Signal cables must not be installed in the same cable tray or
conduit as high-power cables.
 Cables containing insulation materials with different
maximum-rated conductor temperatures should not be
bunched together (that is, in a common clip, gland, conduit
48
401497/B
Cables



or duct). When this is impractical, the cables must be
carefully arranged such that the maximum temperature
expected in any cable in the group is within the
specifications of the lowest-rated cable.
Cables with protective coverings which may damage other
cables should not be grouped with other cables.
Cables having a copper sheath or braiding must be installed
in such a way that galvanic corrosion by contact with other
metals is prevented.
To allow for future expansion of the system, all cables
should be allocated spare conductor pairs. Also, space within
the vessel should be set aside for the installation of extra
cables.
Radio Frequency interference
All cables that are to be permanently installed within 9 m (30 ft)
of any source of Radio Frequency (RF) interference such as a
transmitter aerial system or radio transmitters, must, unless
shielded by a metal deck or bulkhead, be adequately screened by
sheathing, braiding or other suitable material. In such a situation
flexible cables should be screened wherever possible.
It is important that cables, other than those supplying services to
the equipment installed in a radio room, are not installed through
a radio room, high power switch gear or other potential sources
of interference. Cables which must pass through a radio room
must be screened by a continuous metal conduit or trunking
which must be bonded to the screening of the radio room at its
points of entry and exit.
Physical protection
Cables exposed to the risk of physical damage must be enclosed
in a steel conduit or protected by a metal casing unless the
cable’s covering (e.g. armour or sheath) is sufficient to protect it
from the damage risk.
Cables exposed to an exceptional risk of mechanical damage
(for example in holds, storage-spaces and cargo-spaces) must be
protected by a suitable casing or conduit, even when armoured,
if the cable covering does not guarantee sufficient protection for
the cables.
Metallic materials used for the physical protection of cables
must be suitably protected against corrosion.
401497/B
49
HiPAP 502/452/352/102 hull units
Grounding
Grounding connections should be made using a conductor which
has a cross-sectional area appropriate for the current rating of
the cable, or with a metal clamp which grips the metallic
covering of the cable and is bonded to the hull of the vessel.
These cable coverings may also be grounded by means of glands
specially intended for this purpose and designed to ensure a
good ground connection. The glands used must be firmly
attached to, and in good electrical contact with, a metal structure
grounded in accordance with these recommendations.
Electrical continuity must be ensured along the entire length of
all cable coverings, particularly at joints and splices. In no case
should the shielding of cables be used as the only means of
grounding cables or units.
Metallic casings, pipes and conduits must be grounded, and
when fitted with joints these must be mechanically and
electrically grounded locally.
Cable connections
All cable connections are shown on the applicable cable plan
and interconnection diagrams.
Where the cable plan shows cable connections outside an
equipment box outline, the connections are to be made to a plug
or socket which matches the plug or socket on that particular
item of equipment.
Where two cables are connected in series via a junction box or
terminal block, the screens of both cables must be connected
together but not grounded.
Cable terminations
Care must be taken to ensure that the correct terminations are
used for all cable conductors, especially those that are to be
connected to terminal blocks. In this case, crimped sleeveterminations must be fitted to prevent the conductor core from
fraying and making a bad connection with the terminal block. It
is also of the utmost importance that where crimped
terminations are used, the correct size of crimp and crimping
tool are used. In addition, each cable conductor must have a
minimum of 15 cm slack (service loop) left before its
termination is fitted.
50
401497/B
Cables
Cable identification
Cable identification codes corresponding to the cable number
shown in the cable plan must be attached to each of the external
cables. These identification codes should be positioned on the
cable in such a way that they are readily visible after all panels
have been fitted. In addition, each cable conductor should be
marked with the terminal board number or socket to which it is
connected.
Cable planning
All cables must be available at the units, properly installed in
cable ducting.
____________________________________________________________
Caution
All power must be switched off to the system prior to
the cable installation.
____________________________________________________________
Caution
Do not to exceed the physical limitations of the cables.
____________________________________________________________
Note
Special system requirements, adaptions or components may
introduce special drawings and cables.
____________________________________________________________
Note
In order to meet the EMC requirements, dedicated grounding
cables have been used to connect the various system units to the
vessel’s ground. These cables are identified as “X” on the cable
plan drawings. The braided grounding cable required is
supplied with the system.
These cables must not be longer than 1 metre.
____________________________________________________________
The cabling for all HiPAP systems are in principle the same, and
most of the cables are identical. The only system specific cable
is:
 Transducer cable from the transceiver unit to the transducer.
All cables used are specified in the following sections.
Cable specifications
Each individual cable is identified on the cable plans. The cables
fall into two categories:
 Cables provided by the installation yard.
 System cables supplied with the delivery.
401497/B
51
HiPAP 502/452/352/102 hull units
Yard cables
The cables to be provided by the yard are identified as such in
the cable listing.
____________________________________________________________
Note
The cable specifications given are the minimum specifications.
____________________________________________________________
For each cable the following is provided:
 Connection to be made on each end of the cable (including
system units, terminal block identification and plug/socket to
be used).
 Number of cores.
 Recommended cable type.
 Minimum cable specifications.
____________________________________________________________
Caution
Any special requirements must be considered in
addition to those listed. Kongsberg Maritime accepts no
responsibility for damage to the system or reduced
operational performance if this is caused by improper
cabling.
____________________________________________________________
System cables
Several cables will be supplied with the system. Such cables
normally consist of power cables for peripheral equipment, and
interconnection cables for computers and/or operator stations.
These cables are normally delivered (packed) with the units.
Cable connections
All cables must be terminated correctly. The required
information is provided in the applicable interconnection
drawings.
Special cables
Special system applications or requirements may result in
additional or modified cable runs.
52
401497/B
Cables
Transducer to transceiver unit cables installation
Topics

Cable information on page 53

Transducer cable connection on page 53

Cables between the hull unit and the Hoist Control Unit on
page 54
Cable information
Cabling from transducer to transceiver is separated in 2 parts.
 One part is protected inside the hull unit and goes from the
transducer to the junction box.
 The other part goes from the junction box to the
transceiver unit, and is the moving part of the transducer
cable. Then it is possible to replace this part if damaged, or
when connecting to another transceiver type.
 See the HiPAP 502/452/352/102 Instruction manual for
more information.
The cabling from the transducer to the junction box is
standard for all transceiver types. (It is made be 8 round flat
cables placed and protected inside the transducer shaft (installed
at delivery - various lengths, depending on type of hull unit more information).
The cabling from the junction box to the transceiver unit is
the same for all transducer types and hull units but it comes in
two different lengths.

Cable drawing on page 160.
Transducer cable connection
This unit can connect to the transducer with 2 different types of
cable.
 Transducer patch cable
 Old transducer cable with plug.
Detailed description,
see the HiPAP 502/452/352/102 Instruction Manual.
401497/B
53
HiPAP 502/452/352/102 hull units
Cables between the hull unit and the Hoist
Control Unit
This procedure describes how to install the cables between the
hull unit and the Hoist Control Unit.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained electrical fitter.
Ship location - No special requirements.
Special tools - None.
References
Drawings - drawing in the Drawing file chapter from page 146.
Installation procedure
1
Remove the junction box lid.
 Refer to the Cable gland assembly procedure on page 46.
54
2
Dismantle the appropriate cable gland.
3
Thread the various parts onto the cable in the correct
order.
4
Pass the cable into the junction box.
5
Connect the cable terminations into the junction box
terminal block.
- Ensure all connections are made firmly.
- Refer to the diagrams and drawings listed above.
6
Reassemble the cable gland and tighten it to ensure a
water proof seal, ensuring enough slack is left in the cable
so none of the wires is under tension.
7
When all cables have been connected, check the entire
assembly to ensure all the connections are correct and
tight.
8
Replace the junction box lid, using a thin film of silicon
grease on the seal to ensure the box will be water proof.
401497/B
Operation
6
OPERATION
This chapter describes the operation of the HiPAP hull units.
The operation is the same for all types of HiPAP hull units.
____________________________________________________________
Caution
Once the transducer is lowered, the depth of water
under the vessel must be monitored closely.

Max vessel speed - when the transducer is in the lowered
position, refer to information on page 17.
____________________________________________________________
Warning
Important information about remote control
operation – see page 55.
____________________________________________________________
Topics

Hoist control operation on page 55

Hoist control operation from Operator Station/APOS on page
57

Manual operation of the hoist motor on page 57

Gate valve operation on page 63
Related topics

Electrical system principles on page 115
Hoist control operation
The hull unit will normally be controlled from the operator’s
position using the Remote Control Unit (RCU).
Important remote control information
____________________________________________________________
Warning
401497/B
When the system is under remote control the hull
unit will move without warning, so ensure;
- Personnel and equipment are kept well clear
- The gate valve is open.
- Check that the link HTCB1 20 – 21 is not
mounted in the Hoist Control Unit. This to avoid
damaging the transducer when lowering the hull
unit.
Link HTCB1 20 – 21 should only be mounted if the
gate valve with no limit switch is mounted.
55
HiPAP 502/452/352/102 hull units
Always set the rotary switch S1 to STOP before
approaching the hull unit.
____________________________________________________________
If the hull unit must be raised or lowered for maintenance
purposes, the HCU must be used. The HCU is in the vicinity of
the hull unit and the maintenance engineer must have a clear
view of the hull unit while it is being raised or lowered. The
engineer will then be in a much better position to start and stop
the unit as required.
The HCU incorporates a rotary switch, S1, which is used to raise
or lower the hull unit locally.
Figure 5 Hoist Control Unit - switch S1
Before you start lowering/raising the hull unit, check to
ensure that:
1
No maintenance work is being performed on the hull unit.
2
There are no obstructions around the hull unit which could
prevent it from moving (or jam it while it is moving).
Lowering the hull unit
56
1
Ensure that the gate valve is open.
2
Open the HCU door.
3
Set rotary switch S1 to LOWER.
4
Once the hull unit has reached the required position, set
the switch S1 to STOP.
401497/B
Operation
The hull unit will stop automatically when it reaches its
fully lowered position. Once it has stopped, set the
switch to STOP to prevent the unit from moving in
the event of a fault.
5
Close the HCU door.
Raising the hull unit
1
Open the HCU door.
2
Set rotary switch S1 to HOIST.
3
Once the hull unit has reached the required position, set
the switch S1 to STOP.
The hull unit will stop automatically when it reaches its
fully raised position. Once it has stopped, set the
switch to STOP to prevent the unit from moving in
the event of a fault.
4
Close the HCU door.
5
If the hull unit is to be left in fully raised position for some
time, you are advised to close the gate valve.
Stopping the hull unit
If the hull unit must be stopped at any position other than fully
raised or fully lowered, set the rotary switch to STOP at the
appropriate time.
Always set the switch to STOP before commencing
maintenance work on the hull unit.
Hoist control operation from Operator
Station/APOS
Caution
Check the water depth before lowering the transducer
to avoid damaging the transducer.
APOS will automatically display an icon in the toolbar for each
hull unit that is available for remote control.
This icon is displayed when the hull
unit is in the upper position.
Any other position changes the icon to
red colour.
401497/B
57
HiPAP 502/452/352/102 hull units
Operating the Hoist Control from APOS
1
Press the icon to enter the control dialog:
Hoisting the
hull unit
Lowering the
hull unit
(Cd31220)
Figure 6 Hoist Unit Control dialog
-
58
The Figure 6 shows the hull unit in the upper position and
the gate valve open.
In this case all buttons are enabled. One can either lower
the hull unit or close the gate valve.
2
Selecting the
warning dialog:
arrow for the hull unit will first show a
3
Selecting Yes will start lowering the hull unit.
401497/B
Operation
-
4
401497/B
The indicator beside the down arrow will start flashing
while the hull unit moves.
The operation will take approximately 90 seconds for a
standard hull unit. The progress bar to the left will mimic
the operation.
It is possible at any time to stop lowering/hoisting by
pressing the Stop button.
When the hull unit is lowered, the gate valve buttons are
disabled.
When the hull unit is fully extracted, the dialog will look
as shown below:
59
HiPAP 502/452/352/102 hull units
Gate Valve
Opening the gate valve
1
-
Select the Open button to start the operation and the
accompanying indicator will start to flash green.
The gate valve must be fully open before the hull unit
up/down buttons are enabled.
It is possible at any time to stop closing/opening by
pressing the Stop button.
Open the
gate valve
Stop the
operation
(Cd31221)
60
401497/B
Operation
Closing the gate valve
Note
It is only possible to close the gate valve when the hull unit is in
the upper position.
Close the
gate valve
Stop the
operation
(Cd31222)
1
-
401497/B
Select the Close button to start the operation and the
accompanying indicator will start to flash red.
The hull unit signal "Upper position" must be green
before the close operation can start.
The hoist control buttons are disabled if the gate valve is
not fully open.
It is possible at any time to stop closing/opening by
pressing the Stop button.
The gate valve must be fully open before the hull unit
up/down buttons are enabled.
61
HiPAP 502/452/352/102 hull units
Manual operation of the hoist motor
Caution
Check the water depth before lowering the transducer
to avoid damaging the transducer.
A hand crank is provided. It is stowed on the hoist platform
Attach the hand crank to one end of the motor shaft. With this
you can 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, if you are to use the hand crank.
____________________________________________________________
Note
Ensure that power to the hull unit is switched off before using
the handle.
____________________________________________________________
Figure 7 Hand crank stowed
62
401497/B
Operation
Procedure
1
Loosen the hand crank from the hoist platform.
2
Then put on the hand crank on the top of the motor.
3
Tighten the screw (on the top of the motor/gearbox - see
figure below) until you are able to turn the motor shaft
with the hand crank.
Figure 8 Brake mechanism screw
____________________________________________________________
Caution
After the manual operation is complete remember to:
- Loosen the screw.
- Remove the hand crank and put it back into storage.
____________________________________________________________
Warning
For safety reasons, always keep the gate valve
closed when the hull unit is in fully raised position
and the break is released.
____________________________________________________________
Gate valve operation
If a hydraulic system for operation of the gate valve is fitted
(option), the gate valve will normally be open / closed using the
remote / local unit of the hydraulic system.
However, in the event that the gate valve must be closed or
opened for maintenance purposes, use the manual hand wheel.
401497/B
63
HiPAP 502/452/352/102 hull units
7
MAINTENANCE
This chapter contains information on how to perform all normal
preventive and corrective maintenance on the HiPAP hull units
system.
 The procedures are identical for all HiPAP system.
 The technical descriptions included in this manual are
intended to be used by maintenance technician and / or
fitters.
____________________________________________________________
Note
If your organization (or vessel) does not have the appropriate
personnel available, you are strongly advised to contact either
Kongsberg Maritime or your dealer for assistance.
____________________________________________________________
Warning
Kongsberg Maritime accepts no responsibility for
any damage or injury to the system, ship or
personnel caused by drawings, instructions and
procedures not prepared by Kongsberg Maritime.
Neither Kongsberg Maritime nor our dealers will
accept responsibility for damage or injury to the
vessel, system or personnel resulting from
incorrect maintenance performed on the system.
____________________________________________________________
64
401497/B
Maintenance
Topics

Safety on page 65

Before you start on page 66

Maintenance philosophy on page 66

Maintenance schedule on page 67

Shaft sleeve and shaft, special attention on page 67

Watertightness test on page 68

Preventive maintenance on page 69

Corrective maintenance on page 73
Related topics

Torque on page 29

Tools on page 29

Grease for shaft and chain on page 21

Gear oil on page 22

Spare parts on page 104

Drawings in the Drawing file chapter from page 146
Safety
Refer to standard company/vessel safety procedures before
commencing maintenance work.
 See also High voltage safety warning on page II in this
manual.
____________________________________________________________
Note
After any maintenance work, the system must be checked to
ensure it works correctly. Refer to the procedure in the Test and
alignment procedures chapter.
____________________________________________________________
401497/B
65
HiPAP 502/452/352/102 hull units
Before you start
Before you start performing any maintenance, inform the
control room that you are about to carry out maintenance on the
hull unit, and that the hull unit will be switched off while the
maintenance is being carried out.
Maintenance philosophy
The maintenance philosophy recommended by Kongsberg
Maritime is:
 On-board maintenance should be carried out by a
maintenance engineer, with the assistance of the operator.
The maintenance should include the following:
 Calibrations
 Simulations
 Functional tests
 Traditional troubleshooting based on a good knowledge of
the system.
 Replacement of faulty parts should be limited to the line
replaceable units (LRUs) recommended in the spare parts list.
____________________________________________________________
Note
To reduce the number of spare boards required, standard circuit
boards without software may be provided. In the event of a
replacement becoming necessary, the software on the faulty
circuit board must then be transferred to the new board. Any
links and switches on the new circuit board must also be set as
on the old board.
____________________________________________________________
Whenever a faulty unit has been replaced, the unserviceable unit
should be sent to Kongsberg Maritime, or an appointed dealer,
for repair.
____________________________________________________________
Note
If maintenance work must be performed on the “wet” sections of
the hull unit, always perform a watertightness test before
breaking the watertight integrity of the hull unit.
 Refer to page 68
____________________________________________________________
66
401497/B
Maintenance
Maintenance schedule
Maintenance routines must be performed regularly and
effectively to ensure that the equipment is kept in top condition.
Effective maintenance is even more important with the
equipment described in this manual, as a faulty unit could have
disastrous consequences in the presence of an inflammable
atmosphere.
The chart below states the maximum recommended intervals at
which the various routines should be performed - the intervals
should be decreased if the system is used excessively, or if the
maintenance engineer considers it necessary.
Maintenance chart
Routine
Frequency
Hull unit general inspection
Annual
Filling motor gearbox
Annual
Filling shaft sleeve
Annual
Cleaning transducer
Annual
Lubricating drive chains/sprockets
2 months
Lubricating elevator screw and nut
2 months
Cleaning transducer shaft
2 months
Cleaning transducer
Regularly
Inspection of junction box
6 months
Hoist Control Unit general inspection
Annual
Remote Control Unit general inspection
Annual
Gate valve OPEN/CLOSE
2 weeks, if possible
Actuator
Annual
Shaft sleeve and shaft, special attention
Special attention must be given to the shaft sleeve and
transducer shaft. The sleeve contains several seals, and these
will wear as the transducer is lowered and raised. It is therefore
important that you:
401497/B
67
HiPAP 502/452/352/102 hull units



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.
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.
Watertightness test
The hull unit compartment is located in the keel of the vessel
below the water-line. Maintenance on the hull unit must
therefore be carried out with care to ensure that no water leaks
occur.
It is important to check that the gate valve below the hull unit is
closed and watertight before any maintenance procedure is
performed that involves breaking the watertight integrity of the
hull unit.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Anyone trained in the procedure.
Vessel location - Afloat.
Special tools - None.
Procedure
The procedure is as follows:
68
1
Fully raise the hull unit.
2
Switch off all power to the system.
3
Close the gate valve.
4
Check 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
When the water stops flowing, crack open the gate valve
and close it again.
- 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
401497/B
Maintenance
of water flow is because the gate valve is sealed, and
not merely because the air-vent cock is blocked.
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.
____________________________________________________________
Preventive maintenance
Topics

Lubrication on page 69

Hull unit inspection on page 70

Hoist Control Unit inspection on page 72
Lubrication

Refer to Drive chains lubrication on page 78

Refer to Hoist motor, gear box lubrication 74
Several parts of the hull unit must be inspected to ensure the
correct amounts of lubricants are present. The following points
must be checked:
401497/B
1
The gearbox - Oil level shall be to the top screw on the
side of the unit.
- Oil type: SAE 30 motor oil.
- 1 litre of oil is needed if the gear box is empty.
2
The shaft sleeve - The transducer shaft must be covered
with a thin film of grease.
- Grease type: Exxon Mobil Mobilux EP2
(or equivalent)
- Approx. 1.5 kg of grease on shaft sleeve and chains.
3
The drive chains and sprockets - The drive chains must be
lightly greased to ensure smooth operation and prevent
corrosion.
- Grease type: BIRAL VG/HT (or equivalent).
- Approx. 1.5 kg of grease on shaft sleeve and chains.
4
The transducer shaft guide rails - The guide rails ensure
the transducer shaft remains correctly orientated relative to
69
HiPAP 502/452/352/102 hull units
the vessel at all times. These guides must be checked at
regular intervals and adjusted as necessary.
- Grease type: BIRAL VG/HT (or equivalent).
5
Limit switches - The limit switches are activated by
rotating arms. These arms are mounted on bearings, and
are fitted with wheels to reduce friction. A few drops of
oil on the moving parts at regular intervals will help to
keep the switches trouble-free.
Hull unit inspection
The hull unit must be inspected at regular intervals and if it has
not been used for an extended period of time.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained maintenance/inspection engineer.
Vessel location - Afloat.
Special tools - None.
Spare parts - Depending on the results of the inspection.
Procedure
70
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 on completion.
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.
- Leakage rate:
401497/B
Maintenance
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 as 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.
 Refer to procedure on page 79
12
Check that the upper and lower limit switches are securely
and correctly located, and operate correctly.
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.
 Cleaning the transducer - see page 86
 Replacing a zinc anode - see page 95
If necessary, check that the system operates correctly by
performing the system test procedure described in the Test and
alignments procedures chapter.
List of spare parts:

401497/B
Refer to the Spare parts chapter from page 104
71
HiPAP 502/452/352/102 hull units
Hoist Control Unit inspection
The HCU must be inspected at regular intervals, and before use,
if it has not been used for an extended period.
Logistics
Special tools - None.
Spare part - Depending on results of inspection.
References
Drawings:

Drawings in the Drawing file chapter from page 146
Procedure
72
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, and seal on the cables passing
through them.
3
Check also that there is no tension on the cables.
4
Open the HCU.
5
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.
6
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.
7
Check that all component units (relays, breakers, circuit
boards etc.) are tight on their mounting rails.
401497/B
Maintenance
8
Check that all manually operable switches and breakers
operate smoothly.
- Refer to Corrective Maintenance for part replacement
procedures.
9
Refer to Spare Parts for a complete list of the spare parts
available.
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
Corrective maintenance
Corrective maintenance on the hull unit system will be required
when the system malfunctions. The design does not include a
built-in test system, so troubleshooting must be based on the
manuals, drawings and diagrams.
Topics
401497/B

Hoist motor - starting on page 74

Drive chains - starting on page 78

Opening the transducer dock on page 81

Lifting the hull unit on page 83

Transducer - starting on page 84

Transducer cables on page 87

Shaft sleeve - starting on page 91

Zinc anode on page 95

Transducer shaft on page 96

Limit switches on page 97

Gate valve on page 98

Hoist Control Unit on page 102

Test procedure on page 103
73
HiPAP 502/452/352/102 hull units
Hoist motor, gear box lubrication
The oil level in the motor gearbox must be checked at regular
intervals, and new oil must be added when required.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Maintenance engineer.
Vessel location - N/A.
Special tools - None.
Spare parts - Oil type, see page 21.
Figure 9 Hoist motor and gearbox
74
401497/B
Maintenance
220 V wiring
To HCU
(Cd31139)
Power inlet
To upper limit switch
To lower limit switch
Figure 10 Hoist motor connections
Procedure
1
Switch off power to the system in the HCU.
2
Thoroughly clean the gearbox and the surrounding area,
removing all dirt and loose debris (paint flakes etc).
3
Remove the filler cap (A) and the level screw (B).
4
Fill the gearbox with oil to the level hole.
5
Replace the level screw and the filler cap.
6
Wipe off any excess oil or drips.
Hoist motor replacement
Logistics
Safety - Refer to the general safety procedures.
Personnel - Two trained maintenance engineers.
Vessel location - N/A.
Special tools - Lifting apparatus may be required.
Spare parts Motor and gearbox:
331-045952
Motor (stand-alone):
331-084150
Four (4) mounting nuts/washers for motor.
Centa - motor manufacturer, http://www.centa.no.
401497/B
75
HiPAP 502/452/352/102 hull units
Figure 11 Replacing the Hoist motor and/or gearbox
Procedure
1
Switch off power to the system in the HCU.
2
Clamp the transducer shaft to prevent it from sinking
when the motor is disconnected.
3
Open the junction box on the motor, label and disconnect
all the cables.
4
Unscrew the four mounting nuts (C).
5
Pull the motor straight off the gearbox.
If the motor is to be sent away for repair, close the gap in the
motor brake by mounting the cover plate.
(This cover plate was supplied initially with the hull unit, and
was used for this purpose prior to the motor installation.)
Reassembly:
76
1
Insert the new motor, and secure it in position with the
four nuts.
2
Reconnect the cables.
3
Remove the transducer shaft clamp.
4
Perform the system test as described in the Test and
alignment procedures chapter.
401497/B
Maintenance
Hoist motor, gear box replacement
The motor assembly on the top of the gantry comprises two
main parts; the motor and the gearbox. This procedure explains
how to replace the gear box.
Logistics
Safety - Refer to the general safety procedures. Note that the
various parts are heavy.
Personnel - Two trained maintenance engineers.
Vessel location - N/A.
Special tools - A lifting apparatus may be required.
Spare parts Motor and gearbox:
331-045952
Gear box (stand-alone): S62A B3 A+B 1:158.08 Ritzel Ø12.
Four (4) mounting bolts M12x50, M12 nuts, washers and spring
washers.
Procedure
401497/B

Refer to the figure on page 76.
1
Switch off power to the system in the HCU.
2
Clamp the transducer shaft to prevent it from sinking
when the motor is removed.
3
Slacken the drive chains and lift them off the drive
sprockets.
4
Support the motor / gearbox unit then remove the four (4)
mounting nuts/bolts / washers (D) 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 (D).
77
HiPAP 502/452/352/102 hull units
10
Lift the drive chains onto the sprocket wheels, and then
check/adjust the tensions in the chains.
 Refer to procedure on page 79.
11
Reconnect the electrical cables.
12
Remove the transducer shaft clamp
Drive chains lubrication
The drive chains must be kept lubricated to ensure smooth
operation and to prevent corrosion. Inspect the chains at regular
intervals, and before use, if the hull unit has not been used for an
extended period.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Maintenance engineer.
Vessel location - N/A.
Special tools - None.
Spare parts - Grease type, see page 21
Procedure
1
Switch off power to the system in the HCU.
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.
 See below.
78
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.
401497/B
Maintenance
Drive chains tension
To operate correctly without damaging the various shafts and
bearings, the drive chains must be at the correct tension. The
chains’ tensioning devices are located on either side of the base
of the hull unit gantry. There is one device for each drive chain.
The devices raise or lower the lower sprocket bearings
independently, so adjustment of one chain has no effect on the
other.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained maintenance engineers.
Vessel location - N/A.
Special tools - None.
Special tools - 12 mm block. Spring-balance (0 - 15 kg).
Spare parts - None.
Test procedure
401497/B
1
Ensure there is sufficient water below the vessel.
2
Open the gate valve.
3
Lower the transducer shaft to the fully lowered position.
4
Switch off power to the system in the HCU.
5
Place a 12 mm block against the inside of the gantry
frame, midway between the chain sprockets.
6
Using a spring-balance, pull the chain against the block.
- The tensions must be adjusted such that a force of 910 kg is required to pull the chain against the block.
7
Grip the chain at the mid-point between the upper and
lower chain sprockets. Using reasonable force, attempt to
push and pull the chain horizontally in the directions in
which the chain would normally bend.
- It should be possible to move the chain a total of
between 1 and 2 cm.
79
HiPAP 502/452/352/102 hull units
Figure 12 Tensioning the drive chains
Adjusting the tension
80
1
Slacken lock-nut (A) on tension adjustment bolt (B).
2
Slacken sprocket bearing nut (D) by 1/2 turn.
3
Adjust tension adjustment nut (C) to achieve the correct
tension in the chain.
4
Tighten the sprocket bearing nut and the lock-nut.
5
On completion, check the chain tension. It may have
altered as the nuts were tightened.
401497/B
Maintenance
Drive chains replacement
The drive chains transmit the force from the hoist motor to the
transducer shaft, to raise or lower the shaft.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained maintenance engineers/fitters.
Vessel location - N/A.
Spare parts Duplex chain (top)
Duplex chain (bottom)
Guide rail
Guide rail
Joint
529-047577
529-047575
599-051130
599-051126
529-047580
Procedure
Both drive chains should be replaced at the same time.
1
Slacken the chains.
2
Find and remove the joints, and disconnect the chains
from the transducer shaft.
3
Replace the chain.
4
Adjust the tension.
 Refer to page 79
Opening the transducer dock
If the hull unit has a transducer dock, gaining access the
transducer and the other “wet” parts of the hull unit is a simple
operation.
Logistics
Safety - Refer to the general safety procedures. Perform a
watertightness test before breaking the watertight integrity of the
hull unit.
Personnel - Two trained maintenance engineers/fitters.
Vessel location - N/A.
Special tools - Length of hose pipe. Jubilee clip.
Spare parts - Hatch seal 540-084245
401497/B
81
HiPAP 502/452/352/102 hull units
Procedure
1
Raise the transducer to the fully housed position.
2
Switch power off at the HCU.
3
Close the gate valve and perform the watertightness test.
 Refer to page 68
4
Secure one end of a suitable length of hose to the drain tap
on the inspection hatch, and place the other end in the
bilge or in a suitable container.
5
Open the air vent on the top of the inspection dock, and
the drain tap, and drain the inspection dock.
6
Slacken and remove the retaining bolts/nuts around the
inspection hatch perimeter, then using suitable lifting
apparatus carefully remove the inspection hatch.
____________________________________________________________
Warning
Warning The hatch is heavy. If the operation is
being conducted while the vessel is at sea, ensure
the hatch is lashed to prevent it swinging should
the vessel roll.
____________________________________________________________
82
7
Use a sponge or cloths to soak up any remaining water and
wipe clean the interior of the dock and gate valve.
8
Perform the required maintenance routines.
9
On completion of the maintenance work, ensure that no
rubbish, tools etc. have been left in the dock, and then
replace the inspection hatch.
10
Tighten all the hatch bolts to the correct torque.
11
Perform the system test as described in the Test and
alignments procedures from page 129.
401497/B
Maintenance
Lifting the hull unit
If the hull unit does not have a transducer dock, the entire hull
unit must be lifted off the gate valve to gain access to the
transducer.
Logistics
Safety - Refer to the general safety procedures. Perform a
watertightness test before breaking the watertight integrity of the
hull unit.
Personnel - Three to four trained maintenance engineers/fitters
Vessel location - N/A.
Special tools - None.
Spare parts - None.
Procedure
1
Raise the transducer to the fully housed position.
2
Switch off power to the system at the HCU.
3
Close the gate valve, and perform the watertightness test.
 Refer to page 68
401497/B
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 water contents 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.
- If there is not enough headroom above the unit to
enable it to be raised high enough for the engineer to
83
HiPAP 502/452/352/102 hull units
-
gain access to the transducer, the transducer dock may
be pulled to one side and the unit laid on the deck
alongside 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.
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.
15
Reconnect all the electrical cables.
16
Perform the system test as described in the Test and
alignment procedures from page 129.
Transducer replacement
The following procedure describes the removal of the transducer
for repair or service under normal conditions.
 A new transducer can be installed by following the same
procedure in reverse.
____________________________________________________________
Caution
The transducer locating pin and zero mark must be in
the correct positions.
____________________________________________________________
Logistics
Safety - Refer to the general safety procedures. Note that the
various parts are heavy.
Personnel - Three to four trained maintenance engineers/fitters.
Vessel location - N/A.
Special tools - Depending on procedure.
Spare parts - Depending on procedure.
84
401497/B
Maintenance
Procedure
1
Gain access to the transducer.
 Refer to pages 81 / 83
2
Remove loose marine growth, seaweed or mud using a
stiff, plastic-bristled brush and copious amounts of water.
3
Place suitable planks and pads onto the gate valve, then
using the crank handle lower the transducer onto the pads
so it will not fall as the bolts are removed.
Ensure the transducer face is not damaged.
4
Flatten down the lugs on the retention plates (if fitted) and
remove the bolts attaching the transducer to the shaft
flange.
____________________________________________________________
Caution
The transducer weighs approximately 60/30 kg, and
must be securely supported during the removal
procedure.
____________________________________________________________
401497/B
5
Using the crank handle, raise the shaft away from the
transducer.
- The transducer may be retained on the shaft by a
vacuum within the flange, and some force may be
required to remove it.
6
Remove the transducer to an appropriate work area.
Extreme care must be used to ensure the transducer face is
not damaged during the operation.
7
Replace the transducer.
- The replacement procedure is the reverse of the
removal procedure.
- Ensure that the transducer alignment pin is fitted to
orientate the transducer correctly.
- Ensure that the O-rings and lock washers are used.
85
HiPAP 502/452/352/102 hull units
Transducer, marine growth removal
Any marine growths on the transducer face, such as weed or
crustaceans, can dramatically reduce the efficiency and accuracy
of the system. The transducer must therefore be inspected and
cleaned at regular intervals.
 If the hull unit is fitted with a transducer dock, open the
hatch to gain access to the transducer.
 If the hull unit is not fitted with a transducer dock and the
vessel is not in a dry dock, the transducer must be checked
for damage and marine growths either by lifting up the hull
unit, or by sending a diver down.
Logistics
Safety - Refer to the general safety procedures. Perform a
watertightness test before breaking the watertight integrity of the
hull unit.
Personnel - Trained maintenance engineers/fitters.
Vessel location - N/A.
Special tools - Wooden or plastic scraper. Stiff, plastic-bristled
brush.
Spare parts - None.
Procedure
1
Gain access to the transducer.
 Refer to pages 81 / 83
Caution
2
Remove loose marine growth, seaweed or mud using a
stiff, plastic-bristled brush and copious amounts of water.
3
Carefully remove any crustaceans, for example barnacles,
using a round-edged wooden or plastic scraper.
- Take great care to ensure that the face of the
transducer is not damaged.
A wire brush or a high-pressure hose must not be used!
4
86
When all accessible parts of the transducer, the shaft and
the internal surfaces of the dock have been cleaned, dried
and inspected, paint the internal surfaces of the dock with
suitable preservation and anti-fouling paints.
401497/B
Maintenance
Caution
The transducer face, shaft and anodes must not be
painted.
5
Close the hull unit. Refer to point 1 in this procedure.
Transducer cables replacement
HiPAP 350 cable comprises of two separate cables.

Refer to page 53
Logistics
Safety - Refer to the general safety procedures.
Personnel Two to three trained maintenance/electrical engineers.
Vessel location - N/A.
Special tools - None.
Spare parts Cable Y1 (TD end)
Cable Y2 (TC end)

Refer to the Spare parts chapter from page 104
Cable Y1
Cable from the top of the transducer, (bottom of the transducer
shaft) to the top of the transducer shaft, into the junction box.
Procedure
1
Switch off power to the system in the Hoist Control Unit.
2
Switch off power to the Transceiver Unit.
3
Open the transducer dock.
 Procedure on page 81
4
Remove the transducer.
 Procedure on page 84
401497/B
5
Remove the four “extended-head” bolts securing the
support plate.
- Access is through the four holes in the plug plate.
6
Remove the eight bolts located around the circumference
of the connector plate.
87
HiPAP 502/452/352/102 hull units
-
The connector plate should now be free.
7
Open the junction box at the top of the transducer shaft.
Disconnect the flat-cables. 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, and remove the two half-ring plates.
9
Pull up the upper gland block, and remove the o-ring.
- 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.
88
10
Tie a suitable length of rope to the upper connector plate.
11
Withdraw the cable through the transducer dock.
12
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.
13
Tie the rope to the transceiver connector on the new cable
and carefully pull the cable up through the shaft.
14
Once the connector is accessible at the top of the shaft,
remove the rope and continue to pull the cable up by hand.
15
At the appropriate time, feed the upper gland block into
the bottom of the shaft.
16
Orient the seal plate correctly, locate it in the bottom of
the shaft, and then secure it using the four “extended head”
screws.
17
Remove the four spacer screws (located beside the access
holes for the “extended head” screws).
18
Orient the connector plate correctly, locate it in the bottom
of the shaft, and secure it using the eight screws.
Note that the connector plate must be “floating”.
401497/B
Maintenance
Note
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.
19
Remove any twists from the cable in the shaft.
20
Lift the upper gland block up out of the shaft and fit the Orings.
21
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.
Figure 13 Securing the support and connector plate
22
Replace the six socket-head screws to secure the half-rings
in position.
23
Connect the cable in the junction box.
24
Close the junction box.
25
Replace the transducer.
 Refer to page 84
401497/B
89
HiPAP 502/452/352/102 hull units
26
Close the transducer dock.
27
Connect the transducer cable to the transceiver unit, and
replace any cable clips.
28
Perform the system test as described in the Test and
alignment procedures from page 129.
Cable Y2
This cable runs from the junction box to the transceiver unit via
the bracket on the hull unit to the junction box.
Procedure
90
1
Switch off power to the system in the Hoist Control Unit.
2
Switch off power to the transceiver unit.
3
Unplug the transducer cable from the transceiver end.
4
Remove all cable clips etc. that secure the transducer
cable.
5
Open the junction box at the top of the transducer shaft.
Disconnect the d-subs.
6
Remove bolts from nipple plate at the side of the junction
box.
7
Unbolt the cable bracket from the gallows.
8
Replace the cable.
9
Close the junction box.
10
Perform the test described in the Cabling installation
checks on page 137.
401497/B
Maintenance
Shaft sleeve lubrication
The transducer shaft must be inspected at regular intervals and
the shaft sleeve filled with grease as necessary.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained maintenance engineer.
Vessel location - N/A.
Special tools - None.
Spare parts - Grease type, see page 21.
Procedure
1
Switch off power to the system at the HCU.
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).
Part of hull unit
Top
Air vent hole
w/screw
Grease nipple
(Cd31078)
Figure 14 Shaft sleeve lubrication
3
Remove the air vent screw.
____________________________________________________________
Caution
If the vent screw is not removed, the shaft seals can be
damaged.
____________________________________________________________
401497/B
4
Fill the sleeve with grease, until the grease appears at the
air vent hole.
5
Replace the air vent screw.
6
Wipe off any excess grease.
91
HiPAP 502/452/352/102 hull units
Shaft sleeve disassembly
____________________________________________________________
Caution
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.
____________________________________________________________
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 (NI300-170-15) 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.
____________________________________________________________
Logistics
Safety - Refer to the general safety procedures.
Personnel - Two trained maintenance engineers/fitters.
Vessel location - N/A.
Special tools - Entering tool.
Spare parts Grease type - see page 21
Set of seals and bearings - see illustration on page 111.
92
401497/B
Maintenance
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
Remove the transducer cable.
 Procedures on pages 87
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.
401497/B
93
HiPAP 502/452/352/102 hull units
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.
____________________________________________________________
94
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 - see table on page 29.
14
Using new O-rings and lock washer, remount the
transducer.
15
Remount 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 - see
table on page 29.
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.
401497/B
Maintenance

Refer to procedure on page 91
22
If required, adjust the tension.
 Refer to page 80
23
Perform a system test to ensure the hull unit operates
correctly.
Zinc anode, inspection and replacement
Logistics
Safety - Refer to the general safety procedures.
Personnel - Two trained maintenance engineers/fitters.
Vessel location - N/A.
Special tools - None.
Spare parts - Zinc anode, 629-076530
Procedure
1
Switch off power to the system at the HCU.
2
Open the transducer dock.
 Refer to page 81
3
Clean the transducer and transducer dock using a stiff,
plastic-bristled brush and copious amounts of water.
4
Inspect the anodes.
- The anodes are bolted to the underside of the shaft
sleeve.
 Refer to the figure on page 109
- 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.
- Program another inspection for a date some time
before the anodes will need to be replaced.
5
401497/B
On completion, close the transducer dock.
95
HiPAP 502/452/352/102 hull units
Transducer shaft, guide rails adjustment
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained maintenance engineer.
Vessel location - N/A.
Special tools - None.
Spare parts - None.
Procedure
The guide rails ensure the transducer is aligned correctly. When
the shaft is fully lowered there should be no space between the
guide rails and the adjustable sliders.
The guide rails ensure the transducer is aligned correctly. When
the shaft is fully lowered there must be no space between the
guide rails and the adjustable sliders, see (2 and 3) on figure
below.
96
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.
401497/B
Maintenance
Note
These adjustments could affect the system alignment. If in doubt,
contact Kongsberg Maritime AS for assistance.
____________________________________________________________
Figure 15 Shaft top - indicating the adjustable sliders
Limit switches replacement
Two limit switches are mounted on the gantry; one to stop the
drive motor when the shaft is fully down, and one to stop the
motor when the shaft is fully raised. The two limit switches are
identical.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Trained maintenance engineer.
Vessel location - N/A.
Special tools - None.
Spare parts - Limit switch 350-087309
Procedure
401497/B
1
Switch off power from the system on the Hoist Control
Unit.
2
Note the connections, and then disconnect the cables from
the limit switch.
3
Remove the mounting bolts and replace the switch.
97
HiPAP 502/452/352/102 hull units
4
Set up the switches as follows:
a Adjust the lower limit switch so that the springs are
compressed 2-3 mm when the transducer shaft is fully
lowered.
b Retract the transducer shaft fully and adjust the upper
limit switch such that it operates when there is
approximately 15-20 mm clearance between the top of
the transducer adapter and the bottom of the shaft
sleeve.
Gate valve replacement
This procedure explains how to replace the gate valve.
Note
The vessel must be in a dry dock while this procedure is
performed.
Logistics
Safety - Refer to the general safety procedures. Note that the
various parts are heavy.
Personnel - Three to four trained maintenance engineers/fitters.
Vessel location - Dry dock.
Special tools – Two (2) winches or cranes.
One for the hull unit - 1500 kg, and one for the gate valve - 500 kg.
Spare parts Gate valve DN700
Gate valve DN 500
Gate valve DN 350
98

Torque - see table on page 29.

See the Spare parts chapter from page 104
401497/B
Maintenance
Procedure
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 electrical actuator (option) is fitted, it must be removed
before you take out the gate valve.
____________________________________________________________
401497/B
1
Fully raised the transducer.
2
The vessel must be in dry dock.
3
Mount a suitable lifting apparatus to the deck head above
the hull unit, and attach it to the top of the hull unit.
4
Remove all the gantry braces, and disconnect cables as
necessary.
5
Take the weight of the hull unit on the lifting apparatus.
6
Remove the upper and lower mounting nuts/bolts to
unbolt the gate valve from the transducer dock and the
mounting flange.
7
Lift the hull unit clear of the gate valve.
8
Pull the old gate valve out.
- Note that 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.
9
Clean the mating surfaces and replace all O-rings.
10
Manoeuvre the new gate valve into position and lower it
carefully onto the mounting flange.
11
Check that it is aligned correctly, and then secure it into
position.
12
Lower the hull unit onto the gate valve.
- Check that it is aligned correctly, and then secure it
into position.
13
Replace all the gantry braces.
14
Check all electrical cables and connections.
15
Perform the system test described in the:
Test and alignments procedures from page 129.
99
HiPAP 502/452/352/102 hull units
Gate valve position indicator replacement
This procedure explains how to replace the complete gate valve
position indicator.
Logistics
Safety - Refer to the general safety procedures.
Personnel - Two trained maintenance engineers/fitters.
Spare parts - As required.
References
Drawings:
 See drawing in the Drawing file chapter from page 146
Procedure
The positioning indicator is standard. It is mounted directly on
the gate valve with two bolts.
1
Fully raise the transducer.
2
Remove the switch unit.
 Procedure on page 101
3
Remove the gate valve wheel.
4
Unscrew the two bolts holding the positioning indicator
(see figure below).
Figure 16 Position indicator
5
100
To mount the new position indicator unit, proceed in
reverse order.
401497/B
Maintenance
Position indicator switch unit replacement
This procedure explains how to replace a position indicator
switch unit.
Logistics
Safety - Refer to the general safety procedures.
Personnel - One trained maintenance engineers/fitters.
Spare parts - As required. Switch, see mounted switch.
References
Drawings:
 See drawing in the Drawing file chapter from page 146
Procedure
1
Disconnect the switch cable. This is done as follows:
a Unscrew the two screws holding the lid on the top of
the switch unit, see figure below (1).
b Open the switch unit lid, see figure below (2).
c Connection 13 and 14 is used. Refer to Interconnection
diagram, hoisting system.
2
Unscrew the two switch unit fasting screws, see figure
below (2).
Figure 17 Position indicator switch unit
401497/B
3
Remove the defect switch unit.
4
Mounting the new switch unit, proceed in reverse order.
101
HiPAP 502/452/352/102 hull units
Hoist Control Unit
Troubleshooting is based on this manual, drawings and
diagrams, and the engineer’s knowledge of the system.
Logistics
Special tools - None.
Spare part - Refer to the Spare parts chapter from page 104
References
Drawings:
 See drawing in the Drawing file chapter from page 146
Hoist Control Unit parts replacements
The relays and switches within the unit can be replaced
individually. The replacement procedures for these items are
similar.
Procedure
1
Inform the system supervisor that the system will be out of
use while maintenance is performed.
2
Switch off all power to the system and remove the system
fuses on the ship’s supply.
3
Open the door to the cabinet.
4
Identify the defective unit.
 The Hoist Control Unit with Ethernet interface internal layout see figure on page 40.
102
5
Attach identification labels to all cables connected to that
unit, and the terminals to which those cables are
connected.
6
Disconnect the cables.
7
Detach the unit by slackening/removing the appropriate
screws and/or unclipping the unit from the mounting rail.
8
Mount the replacement unit and reconnect the wires.
9
Check the connections against the circuit diagram to
ensure they are correct.
10
Check the cabinet to ensure that all connections are tight.
11
Remove all tools and rubbish.
12
Close the cabinet door correctly.
401497/B
Maintenance
13
Take the appropriate safety measures, and then replace the
fuses.
14
Apply power to the system.
15
Perform a system test as necessary to ensure the
maintenance has been conducted successfully.
Test procedure
General checks
On completion of any maintenance on the hull unit, the system
must be checked to ensure the maintenance was successful and
to ensure the hull unit may be operated safely.
 Refer to the hull unit raise / lower checks on page 139.
System alignment
One of the most important variables that will affect system
accuracy is the alignment of the transducer with respect to the
vessel’s fore-and-aft axis. After any maintenance procedure
which could affect the alignment of the transducer (removal of
the transducer, adjustment of guide rails etc.), or if the
maintenance engineer suspects that the transducer has moved
out of alignment, an alignment test should be conducted. This
may require that the vessel goes into dry dock, so all other
options should be thoroughly investigated first.
The system software can then be set up to take into account any
misalignments in the system. Contact Kongsberg Maritime for
assistance with the alignment checks.
 Refer to the hull unit installation test and alignment
procedure on page 129.
401497/B
103
HiPAP 502/452/352/102 hull units
8
SPARE PARTS
This chapter lists the parts and modules defined by Kongsberg
Maritime as Line Replaceable Units (LRUs). The required
mounting components (such as nuts, bolts, washers etc.) are
identified on the diagrams, but have not been allocated order
numbers as we regard these items as standard commercial parts
available from retail outlets around the world.
Codes used
The following codes are used in the parts lists:
Part no.
-
Kongsberg Maritime’s part number.
Item name
-
The name of the item.
Technical data
-
Technical specifications and any other relevant information.
Drw. ref.
-
Reference number of the production / illustration drawing
where the item is included. If a number is given here, the
drawing will be included in the manual.
Drw. pos.
-
The item’s position number on the drawing referenced above.
No. in sys.
The quantity of the item used in the system. Note that this
information is not provided for standard components such as
nuts, bolts and washers.
Rec. spares
The quantity of the item recommended to be carried as spares
onboard the vessel. Note that this information is not provided
for standard components such as nuts, bolts and washers.
104
401497/B
Laser option
Topics

Repair kits on page 105

Junction box kit for HiPAP hull unit on page 105

Main units spare parts list on page 105

Hull unit assembly spare parts list on page 106

Chains on page 107

Transducer dock on page 109

Transducer shaft sleeve on page 111

Transducer shaft sleeve-top on page 114

Transducer on page 115
Repair kit

Set of seals and bearings (for shaft sleeve),
part. no: KIT-103324
Junction box kit for HiPAP hull unit

401497/B
Junction box kit for HiPAP Hull Unit, part.no: 333287
105
HiPAP 502/452/352/102 hull units
Hull unit assembly spare parts
Part no.
Item name
-
Technical data
331-045952
331-084150
529-084151
350-087309
TDH-089996
Motor with gearbox
Recommended
spares
1
0
-
-
-
-
2
0
1
0
1
0
1
0
S62 DT80N4BM/HF 2WE
Motor alone
DFT80N4BM/HF 2WE
Gearbox alone
Limit switch
HiPAP 500 / 450 Transducer
-
Complete spare parts kit
TDH-212000
HiPAP 350 Transducer
-
Complete spare parts kit
316798
HiPAP 100 Transducer
-
Complete spare parts kit
106
No. in
system
401497/B
Laser option
Chains
Figure 18 Chains and guide rails
401497/B
107
HiPAP 502/452/352/102 hull units
Chains spare parts
Part no.
Item name
-
Technical data
529-047575
529-047577
529-047580
Duplex chain
Joint no. 26
599-051126
Guide rail
599-051130
599-048785
-
2
0
2
0
6
0
2
0
12
0
2
0
2
0
Length = 206.44 mm (13 links)
P = 0.625
599-048786
Recommended
spares
Length = 8305.24 mm (523 links)
-
-
108
Duplex chain
No. in
system
Bracket
Guide rail
Guide support
-
401497/B
Laser option
Transducer dock
Figure 19 Transducer dock O-rings, cocks and zinc anode
401497/B
109
HiPAP 502/452/352/102 hull units
Transducer dock spare parts
Part no.
Item name
Technical data
Recommended
spares
540-045951
O-ring (shaft sleeve - dock)
O-ring (dock – gate valve) – DN350
381.2 x 8.2 MIL413B / SMS1817
1
2 DN350
0
540-095690
O-ring (dock - gate valve) – DN500
522.0 x 8.4 N SKEGA 4666142
Nitril 6370001
1
0
407687
O-ring (dock - gate valve) – DN700
735 x 8 70 Shore A NBR
1
0
Gasket 2,5 m – DN500 & DN350
1
1
Gasket – DN700
1
1
139-086182
Air vent / Drain cock
Stainless steel SS316 3/8” with handle.
Also used on shaft sleeve.
2
1
569-084212
Adapter 3/8” Also used on shaft sleeve.
2
1
381120
90° bend 3/8” Also used on shaft sleeve.
2
1
381121
Pipe nipple 3/8” Also used on shaft
sleeve.
2
1
Zinc anode Coral type Z-5
2
2
599-210019
407702
629-076530
110
No. in
system
401497/B
Laser option
Transducer shaft sleeve
Figure 20 Transducer shaft sleeve with level plug, vent screw and grease nipple
401497/B
111
HiPAP 502/452/352/102 hull units
Transducer shaft sleeve spare parts
112
401497/B
Laser option
Part no.
Item name
Technical data
530-042321
530-086845
540-045897
Bearing
Bearing
Twin-set packing
569-021124
Grease nipple
139-086182
569-084212
540-047661
540-086844
576-024904
599-069243
KIT-103324
599-089850
540-076036
569-021094
-
401497/B
2
0
2
0
1
0
2
1
1
1
2
1
2
1
2
0
1
0
1
0
2
0
1
0
1
0
1
0
1
1
One at top, one at bottom of shaft sleeve
JW441NA79
569-021124
Recommended
spares
One at top, one at bottom of shaft sleeve
-
-
No. in
system
R 1/4”
Grease nipple
R 1/4”
Air vent / drain cock
Stainless steel SS316 3/8” with handle. Also
used on transducer dock.
Adapter 3/8”
Also used on transducer dock.
Groove ring
AUN 150-101
Groove ring
NI300-150-170-15
Lock pin
Mounting ring
Between and below groove rings
Transducer shaft casing, spare parts kit
See note below
Support ring
Scraper ring
DA17-1500-N90
Plug
R 1/4”
113
HiPAP 502/452/352/102 hull units
Part no.
Item name
Technical data
572-017725
Note
Seating gasket
No. in
system
Recommended
spares
1
1
R 1/4”
A spare parts kit is available under order no. KIT-083818. This
kit contains all the above items with the exception of the ball
valve.
Transducer shaft sleeve-top
____________________________________________________________
Note
The mounting components (nuts, bolts, washers etc.) on the
drawing below are considered “standard” hardware items.
Kongsberg Maritime order numbers are therefore not given.
____________________________________________________________
Figure 21 Transducer shaft sleeve - top view with mounting components
114
401497/B
Laser option
Transducer
Figure 22 Mounting the transducer
Standard transducer spare parts
Part no.
Item name
-
Technical data
No. in sys.
Recommended
spares
540-075045
O-ring 149.3 x 5.7 MIL413C
3
-
540-076274
O-ring 180.0 x 4.0 N SKEGA 465833
3
-
540-045548
O-ring 189.5 x 3.0 MIL413B
2
0
540-076355
O-ring 148.82 x 3.53 N
1
0
394521
Vibration absorber for HL2180, HL2770
1
1
392884
Vibration absorber for HL2990, HL3770,
HL4570
1
1
395623
Vibration absorber for HL6120
1
1
401497/B
115
HiPAP 502/452/352/102 hull units
Hoist Control Unit
The Hoist Control Unit with Ethernet interface - internal layout,
see figure on page 40.
Hoist Control Unit spare parts
Part no.
Item name
Drw. ref.
-
Technical data
Drw. pos.
351-093666
251-057328
352-103085
352-075772
-
116
Remote switch
-
Page 40
-
S272-K 2A
-
Current limit 1.8 - 2.6 A
Recommended
spares
1
-
1
-
1
-
2
-
S1
Automatic breaker
Thermal relay
No. in
system
Page 40
F02
Power relay
-
RM738024 24 VDC
-
401497/B
Laser option
9
LASER OPTION
 The laser option is described in the HiPAP Model
502/452/352/102 instruction manual.
401497/B
117
HiPAP 502/452/352/102 hull units
10 EQUIPMENT HANDLING
This chapter describes how to transport, pack and unpack, clean,
preserve and store electronic, electro-mechanical and
mechanical units supplied by Kongsberg Maritime AS.
The units may be supplied as spare parts, or as parts of a
delivery.
Topics
 Transportation on page 118
 Re-packing on page 126
 ESD precautions on page 126
 Temperature protection on page 128
Transportation
Unless otherwise stated in the accompanying documentation,
electronic, electro-mechanical and mechanical units supplied by
Kongsberg Maritime can be transported using all methods
approved for delicate equipment; (by road, rail, air or sea). The
units are to be transported in accordance with general or specific
instructions for the appropriate unit(s), using pallets, transport
cases, or carton boxes as appropriate.
Note
Special local restrictions concerning air transportation may be
applied to units containing certain types of batteries. The units
should be checked and the regulations investigated by the
packer/shipper before the unit is dispatched.
Local transportation
All local transportation must be carried out according to the
same specifications as for the initial delivery. In general, all
units must be handled with care. The carton or case containing
the equipment must be kept dry at all times, and must be
sheltered from the weather. It must not be subjected to shocks,
excessive vibration or other rough handling.
The carton or case will normally be marked with text or a
symbol indicating which way up it is to be placed. Follow any
instructions given and ensure the case is always placed with its
“top” uppermost.
118
401497/B
Equipment handling
The carton or case must not be used for any purpose for which it
was not intended (step, table, etc.), and in the absence of other
information, no other cartons or cases must be stacked on top of
it.
Lifting
A heavy crate will normally be marked with its weight, and the
weights of other cartons or crates will normally be entered on
the packing list.
 You must always check the weight of a crate before
attempting to lift it.
 You must always use lifting apparatus that is certified for the
load.
Heavy units may be equipped with lifting lugs for transportation
by crane within the workshop or installation area. Before a crane
is used, check:
 You must check the applicable weight certificate for the
crane.
 You must check the security of the lifting lugs.
Ensure that all available lifting lugs are used. Ensure the unit
remains under control during the operation to avoid damage to
the unit, equipment or personnel.
Heavy units may be transported using a fork-lift truck. Special
attention must then be paid to the position of the unit’s centre of
gravity. The units must be properly secured to the truck.
Storage prior to installation or use
When a system, a unit or a spare part has been delivered to the
customer, it may be subject to long-time storage prior to
installation and use. During this storage period, certain
specifications must be met.
The equipment must be preserved and stored in such a way that
it does not constitute any danger to health, environment or
personal injury.
401497/B
1
The equipment must be stored in its original transportation
crate.
2
Ensure that the units are clearly separated in the shelves
and that each unit is easily identifiable.
3
The crate must not be used for any purpose for which it
was not intended (e.g. work platform etc.).
119
HiPAP 502/452/352/102 hull units
4
The crates must not be placed on top of each other, unless
specific markings permit this.
5
The crates must not be placed directly on a dirt-floor.
6
Do not open the crate for inspection unless special
circumstances permit so.
- “Special circumstances” may be suspected damage to
the crate and its content, or inspections by civil
authorities.
- If any units are damaged, prepare an inspection report
stating the condition of the unit and actions taken.
Describe the damage and collect photographic
evidence if possible. Re-preserve the equipment.
- If the units are not damaged, check the humidity
absorbing material. If required, dry or replace the
bags, then repack the unit(s) according to the packing
instructions.
7
If the crate has been opened, make sure that is it closed
and sealed after the inspection.
Use the original packing material as far as possible.
Storage temperature and humidity
1
The storage room/area must be dry, with a non-condensing
atmosphere. It must be free from corrosive agents.
2
The storage area’s mean temperature must not be lower
than -30° C, and not warmer than +70° C.
- If other limitations apply, the crates will be marked
accordingly.
____________________________________________________________
Note
Transducers must not be stored in temperatures below -30° C,
or higher than +55° C.
____________________________________________________________
3
The crate must not be exposed to moisture from leakages.
4
The crate must not be exposed to direct sunlight or
excessive warmth from heaters.
Shock and vibration
1
120
The crate must not be subjected to excessive shock and
vibration.
401497/B
Equipment handling
ESD precautions

Refer to the information on page 126.
Inspection
An inspection must be carried out immediately after the units
have arrived at their destination.
 Check all wooden or cardboard boxes, plastic bags and
pallets for physical damage. Look for signs of dropping,
immersion in water or other mishandling.
 If damage is detected externally, you will have to open the
packaging to check the contents.
 Request a representative of the carrier to be present while
the carton is opened, so any transportation damage can be
identified.
 If any units are damaged, prepare an inspection report
stating the condition of the unit and actions taken. Describe
the damage and collect photographic evidence if possible.
Send the inspection report to Kongsberg Maritime as soon as
possible.
 If the units are not damaged, check the humidity absorbing
material. If required, dry or replace the bags, then repack the
unit(s) according to the packing instructions.
Unpacking
Normal precautions for the handling, transportation and storage
of fragile electronic equipment must be undertaken.
____________________________________________________________
Note
If the unit is not to be prepared for immediate use, you may
consider storing it unopened in its original packing material.
However, it may be useful to open the case to check its contents
for damage and retrieve any accompanying documentation.
____________________________________________________________

Check the carton before opening it to ensure it shows no
signs of dropping, immersion in water or other mishandling.
 If the carton shows signs of such damage, refer to the
paragraph covering Inspection on receipt.
 Place the carton on a stable work bench or on the floor with
the top of the carton uppermost.
 In the absence of other instructions, always open the top of
the carton first. The contents will normally have been
401497/B
121
HiPAP 502/452/352/102 hull units
lowered into the carton from above, so this will usually be
the easiest route to follow.
 Care must be used when opening the carton to ensure the
contents are not damaged.
____________________________________________________________
Caution
Do not use a knife to open cardboard cartons - the
contents may lie close to the surface, and may be
damaged by the blade.
____________________________________________________________



If the carton has been closed using staples, remove the
staples from the carton as you open it. This will reduce the
possibilities of scratch injury to yourself and damage to the
contents.
If a wooden crate has been closed using screws, always
remove them using a screw-driver. Do not attempt to prise
the lid off with a crow-bar or similar.
Once the carton is open, carefully remove all loose packing
and insulation material. Check for manuals and other
documents that may have been added to the carton during
packing, and put these to one side. Check also for special
tools, door keys etc.
Electronic and electro-mechanical units
____________________________________________________________
Caution
Beware of the dangers of Electro-Static Discharge
(ESD) both to yourself and to the equipment, when
handling electronic units and components.
____________________________________________________________
Electronic and electro-mechanical units will normally be
wrapped in a clear plastic bag. Lift the unit, in its bag, out of the
carton and place it in a stable position on the floor/work bench.
1
Inspect the unit for damage before opening the plastic bag.
____________________________________________________________
Note
Cables must never be used as carrying handles or lifting points.
____________________________________________________________
Note
Do not break the seal to open a circuit board package before the
board is to be used. If the board package is returned to the
manufacturers with the seal broken, the contents will be
assumed to have been used and the customer will be billed
accordingly.
____________________________________________________________
2
122
Assuming all is well, open the bag and remove the unit.
401497/B
Equipment handling
3
Open the unit and check inside. Remove any packing and
desiccant material that may be inside.
Mechanical units
Mechanical units may be heavy.
1
Using a suitably certified lifting apparatus, lift the unit out
of the crate and place it in a stable position on the
floor/work bench.
2
Inspect the unit for damage and remove any packing
material that may be inside the unit.
Transducers
Transducers may be supplied mounted to a hull unit (if any), or
packed separately. Crates are normally identified by the order
number and the serial number.
The transducer face must be protected by a rigid, padded cover
(e.g. a wooden box lined with foam rubber) all the time it is
exposed to the risk of physical damage.
____________________________________________________________
Note
Once the units are unpacked, great care must be taken to ensure
that transducers and cabling are not exposed to any mechanical
stress. Never lift the transducers by the transducer cable.
____________________________________________________________
Re-packing
If the unit is not to be installed immediately, re-pack it in its
original packing material to prevent damage in the intervening
period.

Refer to the information on page 126.
Storage after unpacking
The equipment should be stored in its original transportation
crate until ready for installation. The crate must not be used for
any purpose for which it was not intended (e.g. work platform
etc.).
Once unpacked, the equipment must be kept in a dry, non
condensing atmosphere, free from corrosive agents and isolated
from sources of vibration.
401497/B
123
HiPAP 502/452/352/102 hull units
____________________________________________________________
Note
Do not break the seal to open a circuit board package before the
board is to be used. If the board package is returned to the
manufacturers with the seal broken, the contents will be
assumed to have been used and the customer will be billed
accordingly.
____________________________________________________________
The unit must be installed in its intended operating position as
soon as possible after unpacking.
If the unit contains normal batteries, these may have been
disconnected/isolated before the unit was packed. These must
then be reconnected during the installation procedure. Units
containing batteries are marked.
____________________________________________________________
Caution
Units containing lithium or alkaline batteries must be
handled separately and with care. Such units are
marked accordingly. Do not attempt to recharge such
batteries, open them or dispose of them by
incineration. Refer to the applicable product data
sheets.
____________________________________________________________
After use storage
If a unit is removed from its operating location and placed into
storage, it must be properly cleaned and prepared before
packing.
Cleaning cabinets
If a cabinet has been exposed to salt atmosphere while it was in
use, it must be thoroughly cleaned both internally and externally
to prevent corrosion.
 Wipe the cabinet externally using a damp cloth and a little
detergent. Do not use excessive amounts of water as the unit
may not be water tight. On completion, dry the unit
thoroughly.
 All surfaces must be inspected for signs of corrosion, e.g.
Flaking / bubbling paint, stains etc. Damaged or suspect
areas must be cleaned, prepared and preserved using the
correct preservation mediums for the unit. The mediums to
124
401497/B
Equipment handling


be used will usually be defined in the units’ maintenance
manual.
All surfaces must be inspected for signs of corrosion, e.g.
flaking/bubbling paint, stain etc. Damaged or suspect areas
must be cleaned, prepared and preserved using the correct
preservation mediums for the unit.
Open the unit, and using a vacuum cleaner, remove all dust
etc. from the unit. Great care must be taken to ensure the
circuit boards and modules are not damaged in the process.
Mechanical units
If a mechanical unit may have been exposed to a salt atmosphere
while it was in use, it must be thoroughly cleaned both internally
and externally to prevent corrosion.
 If the construction materials and type of unit permits, wash
the unit using a high-pressure hose and copious amounts of
fresh water.
Examples:
 The lower parts of hull units (outside the hull)
 Subsea units
 Ensure that all traces of mud and marine growth are
removed. Use a wooden or plastic scraper to remove
persistent growth, barnacles etc. On completion, dry the unit
thoroughly.
____________________________________________________________
Caution
Do not use a high pressure hose in the vicinity of cables
or transducers. Do not use sharp or metal tools on a
transducer face.
____________________________________________________________

If the materials or type of unit prevents the use of a highpressure hose, wipe the unit using a cloth dampened with
water containing a little detergent.
Examples:
 The upper parts of hull units (inside the hull)
 Hydraulic systems
 Do not use excessive amounts of water as some components
on the unit may not be water tight. Wipe off the detergent
with a damp cloth, and then dry the unit thoroughly.
 All surfaces must be inspected for signs of corrosion, e.g.
flaking/bubbling paint, stain etc. Damaged or suspect areas
401497/B
125
HiPAP 502/452/352/102 hull units
must be cleaned, prepared and preserved using the correct
preservation mediums. The mediums to be used will
normally be defined in the unit’s maintenance manual.
Cables
Wipe clean all exposed cables, and check for damage. If a cable
shows signs of wear or ageing, contact Kongsberg Maritime for
advice.
Dehumidifier
Place a suitably sized bag of desiccant material (silica gel or
similar) into the unit to keep the electronic components as dry as
possible.
Coatings
Spray the unit externally with a corrosion inhibitor
(e.g. light oil) before packing.
Re-packing
The unit should be stored and transported in its original packing
material and/or crate. In the event that this material is not
available, proceed as follows:
 Small units must be protected from damp by being placed
within a plastic bag at least 0.15 mm thick. An appropriate
quantity of desiccant material should be placed inside this
bag, and the bag sealed. The sealed unit must then be placed
in an appropriate carton or crate, and supported in the
container by appropriate shock-absorbing insulation
(polystyrene foam chips etc.).
 Large units must be placed in a suitable cardboard box or
wooden crate. The unit must be protected against physical
damage by means of shock-absorbing insulation mats. The
box must be clearly marked with its contents, and must be
stored in a dry and dust-free area.
ESD precautions
What is ESD?
Electro-Static Discharge (ESD) is the transfer of an electrostatic
charge between two bodies at different electrostatic potentials,
caused either by direct contact or induction by an electrostatic
field.
126
401497/B
Equipment handling
The passing of a charge through an electronic device can cause
localised overheating, and it can also “puncture” insulating
layers within the structure of the device. This may deposit a
conductive residue of the vaporised metal on the device, and
thus create a short circuit. This may result in a catastrophic
failure, or degraded performance of the device.
ESD Protection during transport and storage
Sensitive electronic equipment must be transported and stored in
protective packing bags, boxes and cabinets. The equipment
must NOT be transported or stored close to strong electrostatic,
electro-magnetic or radioactive fields.
Unpacking and servicing ESD sensitive equipment
If it is necessary to open and touch the electronics inside the
boxes/cabinets, then the following precautions MUST be taken:
 The working area must be covered by an approved
conductive service mat that has a resistance of between
50 kΩ and 2 MΩ and is connected directly to a reliable
grounding point via its grounding cord.
 The service personnel involved must wear a wrist-band in
direct contact with the skin, connected to the service mat.
 Printed circuit boards and other components should be
placed on the conductive service mat during installation,
maintenance etc.
____________________________________________________________
Caution
If, for any reason, it is necessary to move the circuit
board or components from the conductive service mat,
they must be placed in an approved anti-static
401497/B
127
HiPAP 502/452/352/102 hull units
transportation container (e.g. static shielding bag)
before transportation.
____________________________________________________________

During installation and servicing, all electrical equipment
(soldering irons, test equipment etc.) must be grounded.
Temperature protection
If the unit must be protected against extremes of temperature,
the carton/crate must be lined on all walls, base and lid with 5
cm thick polyurethane or polystyrene foam.
These units will be identified as delicate in the applicable
documentation.
The package must then be clearly marked:
____________________________________________________________
Note
Must not be transported or stored in temperatures below -5
degrees Celsius.
____________________________________________________________
Other units can normally be stored in temperatures
between -30° C and +70° C, refer to the system’s technical
specifications for details.
Transducers must not be stored in temperatures below - 20° C
and above + 60° C.
128
401497/B
Test and alignment
11 TEST AND ALIGNMENT PROCEDURES
This chapter presents checks, tests and alignment procedures
that must be conducted on the hull unit before it is put into
operational service.
Purpose
After the physical installation has been carried out, all the
system units must be checked to ensure that the units have been
installed correctly.
This chapter contains the instructions and procedures required to
ensure the system is installed correctly, is correctly set up and is
safe to switch on and use.
Topics

Test certificate on page 129

Visual inspection on page 129

Test procedures introduction on page 130
Test certificates
Once the testing engineer has performed or witnessed the
performance of a test or part of a test, he should sign on the
dotted line under each check/test to certify that the unit or
system has passed that particular part of the procedure.
The use of these fields is optional, but we recommend that they
are properly filled in for future references.
____________________________________________________________
Note
If the testing engineer is not satisfied with the standard of any
part of the installation, he must contact the personnel who
performed the installation to have the work rectified and
brought up to the required standards.
____________________________________________________________
Visual inspections
After the installation has been carried out, all the system units
must be checked visually to ensure the system has been installed
correctly.
401497/B
129
HiPAP 502/452/352/102 hull units
The testing engineer must ensure that the units have been
mounted in the correct locations, correctly orientated (that is, the
right way up) and are correctly secured to the
bulkhead/deck/mounting brackets. The inspection engineer must
understand that correct installation of some parts of the Hull unit
is critical to the safety of the vessel.
Test procedures introduction
In all cases the step-by-step instructions must be followed if the
tests are to be trustworthy.
In order to verify that the HiPAP system work properly, the
following tests must be carried out:
Topics

Inspection of the hull unit on page 131

Inspection of the Hoist Control Unit on page 135

Cabling installation checks on page 137

Hull unit raise/lower manual checks on page 139

Electrical check on page 141

Remarks and signatures on page 145
Follow the procedures and fill in the tables. Once the system has
been tested, sign the signature page
(use the last page of this section).
The test results will be:
130
OK
when the test is done satisfactory.
FAIL
if the test fails.
NA
if the test is non-applicable.
401497/B
Test and alignment
Inspection of the hull unit
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.
____________________________________________________________
Warning
The correct installation of the hull unit is critical
to the safety of the vessel.
____________________________________________________________
Logistics
Safety - N/A.
Personnel - Experienced engineer from the yard’s quality
assurance department. Installation supervisor.
Vessel location - N/A.
References - This manual.
Special tools - None.
Procedure
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.
401497/B
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.
131
HiPAP 502/452/352/102 hull units
____________________________________________________________
Caution
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.
____________________________________________________________
Caution
If the installation of this part of the hull unit is not
correctly performed, the safety of the vessel will be
compromised.
____________________________________________________________
132
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.
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.
- Type shall be according to Grease for shaft and chain
page 21.
14
Wipe off any excess grease.
15
Check that there is sufficient grease in the shaft sleeve.
- Type shall be according to Grease for shaft and chain
page 21.
- 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
401497/B
Test and alignment
shaft sleeve. Check that the filler and level screws are
tight and not leaking. Clean up any oil spillage.
401497/B
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.
- Type shall be according to Gear oil page 22.
133
HiPAP 502/452/352/102 hull units
Test certificate
Inspection of the hull unit
Item to be checked
Checked (sign)
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
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
Date
Installation team supervisor
Signature
134
Date
401497/B
Test and alignment
Inspection of the Hoist Control Unit
The Hoist Control Unit must be located as close as practically
possible to the hull unit, preferably within the same
compartment. For safety reasons there should be a clear line of
sight between the two units. The Hoist Control Unit is designed
to be bolted to a bulkhead.
Logistics
Safety - N/A.
Personnel - Experienced engineer from the yard’s quality
assurance department. Installation supervisor.
Vessel location - N/A.
References - Drawings included in this manual.
Special tools - None.
Procedure
401497/B
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 using four M8 bolts.
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.
135
HiPAP 502/452/352/102 hull units
Test certificate
Inspection of the Hoist Control Unit
Item to be checked
Checked (sign)
Bolted/Welded
Bolts / ground conductor correct
Paintwork correct
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
Date
Installation team supervisor
Signature
136
Date
401497/B
Test and alignment
Cabling installation checks
This is the test procedures for the system’s power and signal
interface cables.
____________________________________________________________
Warning
These checks must be completed before any
power is switched onto the system.
____________________________________________________________
Logistics
Safety - N/A.
Personnel - Experienced engineer from the yard’s quality
assurance department. Installation supervisor.
Vessel location - N/A.
References - Drawings included in this manual.
Special tools - None.
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 cores 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.
401497/B
137
HiPAP 502/452/352/102 hull units
____________________________________________________________
Warning
These checks must be completed before any
power is switched onto the system.
____________________________________________________________
Procedure
The check procedure will require pairs of engineers, equipped
with the appropriate cable plans and wiring diagrams, two-way
communication devices and tool kits. The “tester” will require
continuity test equipment and the assistant will require a suitable
shorting strap.
____________________________________________________________
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.
____________________________________________________________
Follow the check procedure below for each cable core:
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 cores, and check that the cores 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.
____________________________________________________________
Note
If a low resistance exists between the two cores, this may
indicate the cores are connected to circuits or units with low
internal resistance. If this is the case, disconnect the cores from
the terminal block and test again. The resistance should be
approaching RW. If so:
____________________________________________________________
6
138
The assistant then shorts the two cores together, and the
tester repeats the test. The Resistance should be ≈ 0.
401497/B
Test and alignment
7
The assistant then removes the shorting strap, and the
resistance should go up to ≈ ∞  again.
8
The tester then checks each core’s resistance to ground,
(this should be ≈ ∞ ), and each core’s resistance to all
the other cores in the cable, (this should be ≈ ∞ ).
9
Assuming the test results are correct, the cores 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 cores and
repeat the tests till the entire cable has been checked.
Test certificate
Cable connections and continuity
Item to be checked
Checked (sign)
Connector type
Cable continuity
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
Date
Installation team supervisor
Signature
Date
Hull unit raise/lower manual checks
This procedure is a mechanical test during which the hull unit
is operated manually. These 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.
401497/B
139
HiPAP 502/452/352/102 hull units
____________________________________________________________
Warning
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.
____________________________________________________________
Logistics
Safety - N/A.
Personnel - Experienced engineer from the yard’s quality
assurance department. Installation supervisor.
Vessel location - N/A.
References - Drawings included in this manual.
Special tools - None.
Procedure
140
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.
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.
401497/B
Test and alignment
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 cock.
Test certificate
Hull unit raise/lower manual checks
Item to be checked
Checked (sign)
Manually (by hand crank) lower/rise transducer shaft
Transducer cable free to move
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
Date
Installation team supervisor
Signature
Date
Electrical check
This procedure checks the electrical operation of the hull unit
and sets up the limit switches.
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.
Logistics
Safety - N/A.
Personnel - Min 2 experienced engineer from the yard’s quality
assurance department. Installation supervisor.
Vessel location - N/A.
References –
 Hoist system, Interconnection diagram.
401497/B
141
HiPAP 502/452/352/102 hull units
Special tools - None.
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.
____________________________________________________________
Caution
Check the water depth/clearance under the
ship/transducer before proceeding!
____________________________________________________________
142
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.
401497/B
Test and alignment
13
Release any air which may have accumulated in the
transducer dock and gate valve using the air vent cock.
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 HCU.
- The STOP lamp shall be lit.
19
Press the Reset button (blue) on the protection relay
(F02), in the HCU.
20
Press LOWER/DOWN.
- Verify that the LOWER/DOWN and STOP lamps
are lit when the lower limit is in fully out position.
21
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.
22
Check that the lamp dimmer operates correctly.
Test certificates
401497/B
143
HiPAP 502/452/352/102 hull units
Electrical check
Item to be checked
Checked (sign)
DOWN/UP function-local
Lower limit switch
Upper limit switch
DOWN function-remote
STOP function-remote
UP function-remote
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
Date
Installation team supervisor
Signature
144
Date
401497/B
Test and alignment
Remarks and signatures
Remarks (if any) must be noted here or in a separate report.
Item
Subject
Customer representative
Signature
Date
Kongsberg Maritime representative
Signature
401497/B
Date
145
HiPAP 502/452/352/102 hull units
12 DRAWING FILE
This chapter holds illustrations referred to in various sections in
this manual. The illustrations are based on the original system
drawings and wiring diagrams.
 Unless otherwise noted, all measurements are in millimetres.
 The illustrations are not in scale.
 The original drawings are available in electronic format
upon request.
Drawings
Part No. Rev.
Description
Typical arrangement
302021
A
HiPAP hull unit
N/A
N/A HiPAP hull unit mounting information
Outline dimensions
316242
A
HiPAP HL 2180
316243
A
HiPAP HL 3770
316244
A
HiPAP HL 4570
355186
A
Hoist Control Unit with Ethernet interface
- outline dimensions
Installation/dimensions
830E
DN 350 mounting flange with gate valve
214043
830J
DN 500 mounting flange with gate valve
083045
407806
A
DN 700 mounting flange with gate valve
Cables
W311
C
EMC ground cable
394310
A
Transducer patch cable for all HiPAP
systems
Interconnection and wiring diagrams
343293
A
Hoist system, with hydraulic system, for
activating the gate valve via computer interconnection diagram
334116
B
Hoist Control Unit – wiring diagram
146
Ref.
on page 147 and 148
on page 149
on page 150
on page 151
on page 152
on page 154
on page 157
on page 155
on page 155
on page 158
on page 159
on page 161
on page 162
401497/B
Drawing file
HiPAP hull unit typical arrangement, page 1
401497/B
147
HiPAP 502/452/352/102 hull units
HiPAP hull unit typical arrangement, page 2
148
401497/B
Drawing file
HiPAP hull unit mounting information
401497/B
149
HiPAP 502/452/352/102 hull units
HiPAP HL 2180
Note:
All measurements are in mm.
The drawing is not in scale.
150
CD31140 Page 1 of 1
316242 Rev.A
401497/B
Drawing file
HiPAP HL 3770 page 1
401497/B
151
HiPAP 502/452/352/102 hull units
HiPAP HL 3770 page 2
152
401497/B
Drawing file
HiPAP HL 4570
Note:
All measurements are in mm.
The drawing is not in scale.
401497/B
CD31142 Page 1 of 1
316244 Rev.A
153
HiPAP 502/452/352/102 hull units
Hoist Control Unit – outline dimensions
154
401497/B
Drawing file
DN 700 mounting flange w/gate valve
401497/B
155
HiPAP 502/452/352/102 hull units
DN 500 mounting flange w/gate valve
156
401497/B
Drawing file
DN 350 mounting flange w/gate valve
Note:
The drawing is not in scale.
401497/B
Cd31124 Page 1 of 1
830-214043 Rev. E
157
HiPAP 502/452/352/102 hull units
EMC ground
This cable is used to connect the system unit to the ship’s
ground.
Note that this cable must be as short as possible.
To ship's ground
Unit's ground tag
W311
Rev.C
Ship's ground
Minimum specifications




158
Conductors. 1 x 6 mm2
Screen: None
Voltage: 60V
Max. diameter: N/A
401497/B
Drawing file
Transducer patch cable for all HiPAP systems
401497/B
159
HiPAP 502/452/352/102 hull units
Transducer hull unit cable, for all HiPAP systems
160
401497/B
Drawing file
Hoist system, with hydraulic system for activating the gate
valve via computer - interconnection diagram
401497/B
161
HiPAP 502/452/352/102 hull units
Hoist Control Unit – wiring diagram
162
401497/B
Index
13 CABLE PLAN AND INTERCONNECTIONS
Separate document; Cable plan and interconnections
doc. No 325840.
401497/B
163
14 INDEX
____________________________________________________________
A
FP, 9
Functional tests, 66
Abbreviations, 9
Adjusting the tension, 80
B
Basic cabling requirements, 48
Bilge pump system, 28
Bolt torques, 29
C
Cable connections, 52
Cable connections and continuity, 137
Cable gland assembly procedure, 46
Cable glands, 46
Cable plan and interconnections, 163
Cable specifications, 51
Cable trays, 48
Cables, 45
Connections, 50
Identification, 51
Terminations, 50
Cabling installation checks, 137
Calibrations, 66
Centa, 75
Chains, 107
Contents, 9
Corrective maintenance, 73
G
Gantry, 13
Gate valve, 15, 63
Gate valve position indicator, 15
Switch A, 15
Switch B, 15
Gate valve position indicator, replacement, 100
Gate valve replacement, 98
Gear oil, 22
Gearbox, 13
General checks, 103
Grease for chain, 21
Grease for shaft, 21
Grounding, 50
H
D
dGPS, 9
Dock, 109
DP, 9
Drive chains lubrication, 78
Drive chains replacement, 81
Drive chains tension, 79
E
Electrical check, 141
Electrostatic Discharge (ESD), 126
EMC ground, 158
Equipment handling, 118
ESD precautions, 126
F
HAIN, 9
HCU, 9
HiPAP, 9
HiPAP hull unit, 11
HiPAP hull unit mounting info, 149
HiPAP systems, 12
HiPAP Test and alignment procedures
Purpose, 129
HiPAP/HPR 400 Test and alignment procedures
Remarks and signatures, 145
HL 2180, 18
HL 3770, 18
HL 4570, 18
HL 6120, 18
Hoist control operation, 55
Hoist control unit, 102
Hoist Control Unit, 16, 40
Rotary control switch, 40
Troubleshooting, 102
Hoist Control Unit inspection, 72
Hoist Control Unit parts replacements, 102
Hoist Control Unit with Ethernet interface - internal
layout, 41
Hoist motor, 13, 62
gear box lubrication, 74
Hoist motor, gear box replacement, 77
Hoist motor, replacement, 75
HPR, 9
Hull unit, 12
Remote control, 55
Hull unit general inspection, 70
Hull unit raise / lower manual checks, 139
Hull unit surface protection, 40
Hull units, 12
Packed dimensions and weights, 18
I
Illustrations
Brake mechanism screw, 63
Chains and guide rails, 107
Gate valve with position indicator, 16
Hand crank stowed, 62
HiPAP hull unit system, 11
Hoist Control Unit – maintenance access, 24
Hoist Control Unit - switch S1, 56
Hoist motor and gearbox, 74
Hoist motor connections, 75
Mounting the transducer, 115
Position indicator, 100
Position indicator switch unit, 101
Replacing the Hoist motor and/or gearbox, 76
Securing the support and connector plate, 89
Service dock O-rings, cocks and zinc anode, 109
Shaft sleeve lubrication, 91
Shaft top - indicating the adjustable sliders, 97
Tensioning the drive chains, 80
Transducer shaft sleeve - top view with mounting
components, 114
Transducer shaft sleeve with level plug, vent
screw and grease nipple, 111
Important information, 55
Important remote control information, 55
Inspection of the hoist control unit, 135
Inspection of the hull unit, 131
Installation, 25
Accuracy, 34
DN 350 mounting flange, 34
DN 500 mounting flange, 33
DN 700 mounting flange, 33
Gantry, 38
Gate valve, 35
Hoist motor mounting, 39
Important information, 30
Location, 31
Mounting flange, 33
Procedure, 35
Installation information, 30
Installation procedures, 32
Installation requirements, 45
Installation.Tolerances, 34
J
Junction box kit for HiPAP hull unit, 105
L
Laser, 117
LBL, 9
Lifting the hull unit, 83
Limit switches replacement, 97
Line Replaceable Units, 9
Lowering the hull unit, 56
LRU, 9
Lubrication, 22, 69
Lubrication equivalents, 22
M
Maintenance, 64
Chart, 67
Safety, 65
Manual operation of the hoist motor, 62
Marine growth removal, 86
Mounting flange, 14
MTBF, 9
N
Nut torques, 29
O
Operation, 55
Original packing crate, 119
O-ring, 36
P
Physical protection, 49
Precautions, 27
Preventive maintenance, 67, 69
Preventive maintenance schedule, 67
Protection, 127
R
Radio Frequency interference, 49
Raising the hull unit, 57
Remote Control Unit, 55
Repair kit, 105
Replacements, 66
Requirements, 27
Storage temperature, 120
Supply conditions, 26
System alignment, 103
System cables, 52
S
Securing and terminating the cables, 47
Service dock, 81
Shaft sleeve, 14
Shaft sleeve disassembly, 92
Shaft sleeve lubrication, 91
Shock and vibration, 120
Simulations, 66
Sonar room requirements, 27
Spare parts, 104
Chains, 108
Dock, 110
Hoist Control Unit, 116
Hull unit assembly, 106
Standard transducer, 115
Transducer shaft sleeve, 112
Special attention, 67
Special cables, 52
Special tools, 29
Specification
DN 350 gate valve, 20
DN 350 mm mounting flange, 20
DN 500 gate valve, 20
DN 500 mm mounting flange, 20
DN 700 gate valve, 20
DN 700 mm mounting flange, 20
Gate valve, 20
HL 2180 Gantry, 19
HL 3770 Gantry, 19
HL 4570 Gantry, 19
Mounting flange, 20
Raise and lower motor, 21
Transducer units, 24
Standard tools, 29
Standard transducer spare parts list, 115
Stopping the hull unit, 57
Storage humidity, 120
T
Technical specifications, 17
Temperature protection, 128
Test and alignment procedures, 129
Test certificates, 129
Test procedure, 103
Torque, 29
Traditional troubleshooting, 66
Transceiver unit, 12
Transducer, 12, 15, 115
Transducer cables replacement, 87
Transducer dock, 14
Transducer replacement, 84
Transducer shaft, 15
Transducer shaft sleeve, 111
Transducer shaft, guide rails adjustment, 96
V
Ventilation, 27
Vessel speed, 17
Visual inspection of the cabling, 137
Visual inspections, 129
W
Watertightness test, 68, 81
Y
Yard cables, 52
Z
Zinc anode, 95
Zinc anode, inspection and replacement, 95
">