Datem Neptune 5000 User manual

Neptune 5000
© Copyright Datem Limited 2014 1
Neptune 5000
Technical Manual

Technical Manual
2
Revision History
Page
Number
Issue
Date Description Authority
All Sections 1 21/07/08 Issued to MS. MS
Multiple 2 16/03/10 Electronics Update. MS
All 3 22/07/11 Issued to MS MS
All 4 10/12/12 Client Release AB
All 5 19/03/13 Client Release MS
All 6 05/02/14 Client Release MS
All 7 22/10/14 Client Release AB
This document is the property of DATEM and should not be disclosed without prior written
consent.

Neptune 5000
© Copyright Datem Limited 2014 3
Contents
Re ision History ..................................................................................... 2
Introduction ........................................................................................... 8
System O er iew ................................................................................ 8
System Specification ............................................................................ 9
General System Maintenance ................................................................ 9
Software .............................................................................................. 10
Description ........................................................................................ 10
Specification ...................................................................................... 10
Operational Information ...................................................................... 10
Maintenance ...................................................................................... 10
Trouble Shooting ................................................................................ 11
Topside Control Box ............................................................................... 12
Description ........................................................................................ 12
Specification ...................................................................................... 13
Electrical Installation ........................................................................... 13
Topside Power Supply PCB ................................................................... 16
Topside Telemetry Board ..................................................................... 18
LCD Displays...................................................................................... 20
Maintenance ...................................................................................... 21
Frame Assembly .................................................................................... 22
Description ........................................................................................ 22
Specification ...................................................................................... 22
Assembly .......................................................................................... 22
Maintenance ...................................................................................... 23

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Compensator Assembly ......................................................................... 25
Description ....................................................................................... 25
Specification ..................................................................................... 26
Assembly .......................................................................................... 26
Operational Information ..................................................................... 28
Maintenance ..................................................................................... 28
Transformer Pod Assembly .................................................................... 31
Description ....................................................................................... 31
Specification ..................................................................................... 33
Assembly .......................................................................................... 33
Electrical Installation .......................................................................... 35
Operational Information ..................................................................... 37
Maintenance ..................................................................................... 37
Electronics Pod Assembly ....................................................................... 38
Description ....................................................................................... 38
Specification ..................................................................................... 40
Subsea Power Supply PCB .................................................................. 41
Subsea Connector PCB ....................................................................... 42
Subsea Microcontroller Board .............................................................. 45
Subsea Telemetry Board ..................................................................... 47
In erter Pod Assembly .......................................................................... 49
Description ....................................................................................... 49
Specification ..................................................................................... 50
Assembly .......................................................................................... 51
Motor / Gearbox Assembly ..................................................................... 59

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© Copyright Datem Limited 2014 5
Description ........................................................................................ 59
Specification ...................................................................................... 59
Assembly .......................................................................................... 59
Maintenance ...................................................................................... 60
Thruster Assembly ................................................................................. 61
Description ........................................................................................ 61
Specification ...................................................................................... 61
Assembly .......................................................................................... 61
Maintenance ...................................................................................... 65
Chassis ............................................................................................. 65
Mechanism ........................................................................................ 65
Bearing Housing ................................................................................. 67
Assembly .......................................................................................... 67
Straightener ...................................................................................... 68
Slip-ring ............................................................................................ 73
Cone .................................................................................................... 75
Description ........................................................................................ 75
Specification ...................................................................................... 76
Assembly .......................................................................................... 76
Operational Information ...................................................................... 79
Maintenance ...................................................................................... 80
Cone Rod Assembly ............................................................................... 81
Description ........................................................................................ 81
Specification ...................................................................................... 81
Assembly .......................................................................................... 81

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Operational information ...................................................................... 82
Cone-rod Remo al ............................................................................. 82
Cone-Rod Fitting ............................................................................... 83
Maintenance ..................................................................................... 87
Encoder Assembly ................................................................................ 88
Description ....................................................................................... 88
Specification ..................................................................................... 89
Assembly .......................................................................................... 89
Operational information ...................................................................... 89
Maintenance ..................................................................................... 91
Cone-Up Sensor Assembly ..................................................................... 93
Description ....................................................................................... 93
Specification ..................................................................................... 93
Assembly .......................................................................................... 94
Operational Information ..................................................................... 96
Maintenance ..................................................................................... 96
Altimeter Assembly ............................................................................... 97
Description ....................................................................................... 97
Specification ..................................................................................... 97
Assembly .......................................................................................... 97
Operational information ...................................................................... 97
Maintenance ..................................................................................... 98
Fault Finding ........................................................................................ 99
Tools and Equipment ............................................................................ 100
Recommended Mechanical Tool Kit ..................................................... 100

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© Copyright Datem Limited 2014 7
Recommended Electronics Tool Kit ..................................................... 100
Recommended Specialist Tools ........................................................... 100
Appendix A ......................................................................................... 101
Sample instructions for the wirelock® kit. ........................................... 101
Appendix B ......................................................................................... 103
Material safety data sheet for wirelock® kit. ........................................ 103
Appendix C ......................................................................................... 109
Material safety data sheets for loctite 242 threadlocker. ........................ 109
Appendix D ......................................................................................... 114
Material safety data sheets for HM10 hydraulic oil. ............................... 114

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Figure 1: Neptune 5000 CPT System
This document and the content is ©Copyright Datem Limited 2014. No part of this
document may be copied in any way for commercial redistribution, republication, or
dissemination without the explicit written permission of Datem Limited.
Introduction
System Overview
Neptune 5000 Mk II is the Hea y Duty Cone Penetration system designed and
manufactured by Datem. The system uses the Datem Digital Cone to pro ide
accurate in-situ soil data from the transition zone to water depths up to 3000
metres, and will allow seabed penetration of up to 20 metres.
The system consists of the subsea thruster and frame, illustrated in figure 1, a
topside control box for powering the system and pro iding computer
connection, and Datem’s dedicated PC software for control and data
acquisition.
There are a ariety of optional extras that can be purchased from Datem for
use with this system, but this technical manual only co ers the basic features.
Additional technical manuals are a ailable for the optional features. This

Neptune 5000
© Copyright Datem Limited 2014 9
document is intended to gi e technical staff a basic understanding of the
o erall system, its assemblies, and rele ant information to enable routine
maintenance and repair.
System Specification
Dimensions 2.1m * 2.1m * 2.6m
Weight in Air 4000kg approx
Weight in Sea Water 3500 kg approx
Maximum Operating Pressure 300Bar
Thrust Capacity 35kN
Maximum Penetration 20 Metres
Water Depth 3000 Metres
Power requirement 240Vac 1ph 50/60 Hz, 16A
Penetration Speed
2cm/sec ±10%
Retraction Speed 5cm/sec approx.
Cone 5cm
2
/ 10cm
2
/ Custom
Cone Type Non Subtraction Piezo Digital Cone
Frame Inclination Resolution 1.0°
Acquisition RS 232 19,200 baud
Cone Data Rate Selectable up to 20Hz
Frame Sensor Data Rate 1 Hz
Topside Software Windows 7, Vista & XP Compatible
General System Maintenance
When the system is in operation, it should be washed down with clean, salt-
free water whene er it is returned to the deck of the ship. This will reduce
corrosion, and re eal any damage to the frame, pods, compensator, thruster,
or cables.
The electrical cables connected to the sensors, pods, and auxiliary equipment
should be isually inspected regularly to ensure there are no chafes or cuts in
the insulation. The connectors on both ends of the cables should be tightly
fitted with no face gap, and the lock-rings should be finger-tight.
All fastenings should be regularly checked to ensure they are present, tight,
and there is no damage to them or the items they are fitted to.
Reference should be made to the following sections of the manual to fulfil
detailed maintenance requirements, rele ant to each indi idual sub-system
during operation.

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Software
Description
The system operation is controlled directly from a Topside computer running
dedicated Neptune 5000 control and data acquisition software. Transmission
from the PC uses either standard RS232 protocol at 19,200 baud or Ethernet.
The data is transmitted to the telemetry system housed in the Topside Control
Box.
Specification
The Neptune 5000 control and acquisition computer software requires a
Personal Computer (PC) that meets the following minimum requirements.
Operational Information
Please refer to the Software manual for information on operating the Control
and Data Acquisition Software.
Maintenance
The only means of maintaining the software is to ensure that the hard dri e
has plenty of space and that running processes on the computer are kept to a
minimum, thus allowing the software to run at maximum speed with no delay.
Remo ing any unwanted applications can be achie ed by na igating to the
computers control panel and then selecting “Add/Remo e Programs”.
It is also good practice to regularly run the Scandisk software (recommended
once e ery month), to ensure that the hard disk is in good condition. Another
recommendation is to ensure that good housekeeping practices are adopted
with regards to file names and locations. This enables the data files from e ery
push job to be located easily and quickly.
Processor
2.0 GHz
Spare Hard Disk Space
80 GB
Memory
2.0 GB RAM
Graphics
128 MB
Resolution (Viewing Area)
1024 x 768 minimum
Ethernet Port
1 For Ethernet Communication
Operating System
Windows 7, Vista, XP

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© Copyright Datem Limited 2014 11
Trouble Shooting
Where problems are encountered with software, it is generally related to the
installation and un-installation of other software on the PC. The recommended
solution to such problems is to re-install the Neptune 5000 software, using the
installation CD ROM pro ided.
If communication cannot be established when running the software a mis-
configured communication port could be the cause. Ensure that the Ethernet
communication IP addresses are assigned correctly:
IP Address: 192.168.0.55 - 192.168.0.255 (between 55 and 255)
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.0.54

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Figure 2: Topside Control Box
Topside Control Box
Description
The Topside Control Box, illustrated in Error! Re erence source not ound.,
is housed in a shock mounted IP65 enclosure. It contains the main system
Topside Transformer, Power Supply Board, Telemetry Board, Data Coupling
Board and LCD Displays.
The Topside Control Box has three connectors on the front. These are a
network connection for Ethernet, a 3 pin male for mains power in, and a 3 pin
female for high oltage power out and the superimposed data. There are also
two LCD displays, one for system current and one for the system high oltage,
and four illuminated push button switches. Three cables are supplied for use
with the Topside Control Box, Mains Supply, PC Ethernet and High Voltage
Deck Umbilical. Only these supplied cables should be used with the system.
Always ensure that all the cables are fitted correctly before supplying power to
the Topside Control Box. When power is supplied, the “MAINS POWER” red
push button switch will illuminate indicating that the supply is a ailable and
the Topside Control Box is in Standby mode. To switch on the Topside Control
Box, press the “MAINS POWER” green push button switch. The LCD displays
will switch on, the “MAINS POWER” green push button switch will illuminate,
the “MAINS POWER” red push button switch will go out and the “HIGH
VOLTAGE” red push button switch will illuminate. The Topside Control Box is
now li e but the CPT high oltage supply is not on.

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© Copyright Datem Limited 2014 13
To switch on the CPT high oltage supply, press the “HIGH VOLTAGE” green
push button switch. This green button will illuminate and the “HIGH VOLTAGE”
red push button will go out. The subsea CPT is now li e.
Specification
Dimensions
0.4m x 0.6m x 0.8m Nominal
Weight
46 Kg
IP rating
65
Power requirement
240Vac 1ph 50/60 Hz, 16A from on
line
UPS with adjustable output oltage
Umbilical Out
put
650Vac 1ph 50/60 Hz
Meter Readings
System current
Umbilical HV oltage.
Main Fuse rating
MCB: 16A Type B
WARNING:
Appropriate safe working practices should be followed to ensure that all
hazards are minimised. It should be noted that although the power
switches may be turned off, there are still li e terminals inside the box.
Electrical Installation
Wiring schematic diagrams of the Topside Control Box are illustrated on the
following pages. It should be noted that none of the circuit boards used in the
Topside Control Box contain any user ser iceable parts, other than fuses. For
this reason there are no circuit board diagrams included in the manual. The
indi idual circuit boards are co ered in greater detail later in this document.

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Figure 3: Topside Control Box Wiring Schematic

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© Copyright Datem Limited 2014 15
Figure 4: Topside Control Box Wiring Layout

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Figure 5: Topside Power Supply Board
Topside Power Supply PCB
Overview
The Topside Power Supply PCB pro ides the power needed by the Topside
Telemetry PCB, the High Voltage and Mains Current sensing circuits, and the
LCD displays. The Topside Power Supply Board is illustrated in Error!
Re erence source not ound.. The board contains the sensing circuits used
to measure the umbilical High Voltage and the Mains Input Current and
outputs these measurements for indication on the oltmeter and ammeter
displays.
Topside Power Supply Circuit Description
The Topside Power Supply Board has the following plug connections:
PL1 Supply input to the Current Sensing Circuit
PL2 Supply output from the Current Sensing Circuit
PL3 Supply input to the High Voltage Sensing Circuit
PL4 Supply Output from the High Voltage Sensing Circuit
PL5 Sensor output to Voltmeter Display
PL6 Sensor output to Ammeter Display
PL7 Voltmeter Display power
PL8 Ammeter Display power
PL9 Telemetry PCB Power
The supply input on PL1 passes through the current sensing circuit and is then
split to pro ide power to the power supply circuitry before passing to PL2.

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© Copyright Datem Limited 2014 17
The Power Supply Circuitry pro ides +15Vdc, -15Vdc, +5Vdc, -5Vdc and 0V.
The +/-15Vdc and 0V is used to power the Topside Telemetry Board and the
+/-5Vdc and 0V is used to power the sensing circuits and the LCD displays.
Green LED indicators show the status of the four dc oltages. During normal
operation all four indicators will be illuminated. If any are not illuminated this
is indicati e of a fault and the Topside Control Box should be switched off. The
fault should be in estigated and rectified before switching on the Topside
Control Box.
The Current Sensing Circuit consists of a current sensing transformer (CT1)
and amplification stage. The ammeter signals are output on PL6, and PL8
pro ides the +/-5Vdc power to the ammeter display.
The High Voltage output from TXF1 connects to the Topside Power Supply
Board on connector PL3. It then passes through the high oltage sensing
circuitry and then exits the board on PL4. The high oltage sensing circuit
comprises a di ider network, isolating transformer (TR1) and a bridge rectifier.
The oltmeter signals are output on PL5, and PL7 pro ides the +/-5Vdc power.
The Topside Power Supply Board has only one fuse, FU1. This pro ides
protection for the power supply components only. If this fuse blows this is
indicati e of a fault and the Topside Control Box should be switched off. The
fault should be in estigated and rectified before switching on the Topside
Control Box.
WARNING
Whene er the Topside control box is switched on the Topside Power
Supply Board could ha e both 240 ac and 650 ac on arious exposed
components
Specification
Supply Input
240Vac
+/
-
10%
Supply Input Current
500mA
Low Voltage Outputs
+/
-
15Vdc
, +/
-
5Vdc
Fuse ratings
FS1: 1A

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Figure 6: Topside Telemetry PCB mounted on Adapter
Topside Telemetry Board
Overview
The Topside Telemetry PCB, illustrated in Error! Re erence source not
ound. and the Topside Data Coupling Board, illustrated in Error! Re erence
source not ound., pro ide the telemetry link with the Subsea Telemetry PCB
located in the Subsea Electronics Pod and the Subsea Data Coupler PCB
located in the Subsea Transformer Pod.
The telemetry system gi es a transparent, full-duplex serial link between the
Topside PC and the Subsea Microcontroller capable of transferring data at
19200 baud. The digital information is superimposed on the high- oltage CPT
supply by means of frequency-shift keying (FSK). The Topside Telemetry
Board transmits using a different carrier frequency than the Subsea Telemetry
Board (1.00MHz and 1.37MHz, respecti ely), so that the data reception circuit
is able to decode alid subsea messages while filtering out its own
transmissions.

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© Copyright Datem Limited 2014 19
Figure 7: Data Coupler PCB
The Data Coupler PCB is used to superimpose Topside FSK data on to the high
oltage CPT supply and, con ersely, to reco er FSK data from the Subsea
Telemetry PCB. The high oltage supply is connected to the data coupling
board ia J1. The data is passed to J2, the gold coax connector, which is in
turn connected to the telemetry board.
Since the oltage le els of the reco ered FSK data are dependent on the
length of the umbilical cable, both telemetry boards carry out an automatic
“tuning” sequence during power-up, in order to set the reco ery threshold
oltage. If, for example, power has been applied to the Topside Control Box
but not to the subsea CPT, the Topside Telemetry PCB will repeat its tuning
sequence until the Subsea Telemetry Board has been powered up. Once
communication has been established, each board continuously transmits a
“handshake” message while checking for recei ed handshake messages. (This
process is independent of any communications between the Topside PC and
the Subsea Microcontroller.) A breakdown in telemetry communications,
indicated by a loss of handshake messages, immediately causes both boards
to repeat the tuning sequence.
LED Indicators
Se en LED indicators are fitted to the Topside Telemetry Board. Three green
LEDs show the power supply status: “+15V” and “-15V” are generated by the
Topside Power Board, while “+5V” is deri ed from the +15V supply by an on-
board oltage regulator. Four yellow LEDs monitor communications acti ity:
“Rx0” is illuminated whene er a character is recei ed from the Topside PC;

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Figure 8: LCD Voltmeter and Ammeter Displays
“Tx0” when a character is transmitted to the Topside PC; “Tx1” when a
character is transmitted to the Subsea Telemetry Board; “Rx1” when a
character is recei ed from the Subsea Telemetry Board.
Automatic Tuning
The automatic telemetry tuning sequence takes approximately 5 seconds if
both telemetry boards are acti e and there are no hardware faults. During
tuning, the “Tx1” LED is illuminated, while the “Rx1” LED turns on and off at
about 1 second inter als. Once two-way communication has been established,
both “Tx1” and “Rx1” will blink ery rapidly at about equal intensity, showing
that handshake messages are being transmitted and recei ed. After a
successful tuning sequence the Topside Telemetry Board stores its tuning
results together with those obtained from the Subsea Telemetry Board. These
results are displayed on the Engineering Screen of the Neptune 5000 program.
(“Le el” is a code related to the recei ing circuit threshold oltage; “Quality” is
a alue corresponding to the number of consecuti e alid tuning strings
recei ed while ramping up the threshold oltage – the “Quality” alue
decreases as the umbilical length increases.) If the tuning sequence keeps
repeating, it may be that the Subsea Telemetry Board is not powered up or
the umbilical is not connected.
LCD Displays
The Topside control box has two LCD display modules mounted behind
Perspex windows on the front panel. The display modules are factory set up to
display either System Umbilical Voltage or Topside control box Mains Current
input.