Humphree HCS-5 User manual

HCS-5
HCS-5
For software versions 5.7.x
INSTALLATION MANUAL
FIN AND INTERCEPTOR

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Interceptor Safety Information . . . . . . . . . . . . . . . . . . . . 3
Fin Safety Information . . . . . . . . . . . . . . . . . . . . . . . 4
IMPORTANT NOTICES . . . . . . . . . . . . . . . . . . . . . . . 5
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MOUNTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . 7
INTERCEPTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . 11
Installation without Mounting Plate. . . . . . . . . . . . . . . . . . 11
Installation with Mounting Plate . . . . . . . . . . . . . . . . . . . 16
Painting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . 27
FIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 28
RCU INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 29
CONTROL PANEL INSTALLATION . . . . . . . . . . . . . . . . . . 30
GPS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 31
CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 32
GPS Cable Connection. . . . . . . . . . . . . . . . . . . . . . . 32
Control Panel and RCU Connection . . . . . . . . . . . . . . . . . 32
Servo Cable Installation . . . . . . . . . . . . . . . . . . . . . . 33
RCU Cable Installation . . . . . . . . . . . . . . . . . . . . . . . 33
End Termination Plug Installation . . . . . . . . . . . . . . . . . . . 33
EXTBUS and Analog Interface Cable Installation . . . . . . . . . . . . . 34
Key Switch Installation . . . . . . . . . . . . . . . . . . . . . . . 35
Power Supply Cable . . . . . . . . . . . . . . . . . . . . . . . . 35
START UP THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 36
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Contents

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
SAFETY INFORMATION
General
Please read the manual carefully before operating the Humphree system and pay extra attention to the following
safety notices:
WARNING!
●Make sure to read all Warnings thoroughly as they contain important safety information.The Humphree
system can cause serious injuries or death if not used properly.
IMPORTANT!
●The Important notices contain important instructions to avoid damage or malfunctions on the Humphree
system or other property.
NOTE!
●A note contains information that facilitates the work when operating the Humphree system.
Interceptor Safety Information
WARNING!
When installing the interceptors, make sure that there is no electrical current connected to them.
Isolate shore electrical current to the engine block, battery charger, or accessories mounted on the
engine.
WARNING!
Sharp edges, watch your fingers.

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Fin Safety Information
WARNING!
Before docking, make sure the Humphree system is turned off by the main switch.
WARNING!
Before installation or service, the electrical power to the servo units with dedicated power supply must
be switched off.
WARNING!
Fins must be in neutral position before the boat is lifted out of the water.The lifting device and/or
struts must be placed in such a way that the fins are not damaged.To create a safe workplace in the
area around the ns, it is recommended to have an enclosed area of at least 1.5 x n length 360°
around the n.
WARNING!
There is a risk of being squeezed between the fin and the hull when working in the area of the fin.
Work with caution in the area around the fins.
WARNING!
The fins are rotating when enabled in ZERO SPEED STABILIZATION mode. Swimmers must stay away
from the fins due to the risk of injury. For safety around the vessel, make sure the installer has applied
appropriate warning signs prominently on the hull above the waterline above each fin.
NO SLINGS NO SWIMMING

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
IMPORTANT NOTICES
●The following manual is provided for Humphree service workshops, ship-builders, machine manufacturers,
and other authorized workshops that have personnel with qualied professional training. The installation
instructions are only for professionals. If the installation instructions are not followed or if the work is carried
out by non-professional personnel, Humphree will not assume any liability for damage that may incur to
materials or personal injury.
●The information in this document is the property of Humphree and may not be copied or communicated to
a third party, or used for any purpose other than that for which it is supplied, without the express written
consent of Humphree.This information is given in good faith based upon the latest information available to
Humphree, no warranty or representation is given concerning such information, which must not be taken
as establishing any contractual or other commitment binding upon Humphree or any of it subsidiary or
associated companies.
●If the manual is lost or worn, see www.humphree.com or contact your local Humphree dealer.
●The contents of the manual and equipment specications are subject to change without notice.
●All illustrations in the manual are schematically correct but may not be exact copies of the corresponding
equipment on your vessel.
●The screens shown in the manual may not match in detail the screens you see on the display.The screens you
see depends on software versions, system conguration and system settings.
●Humphree will assume no responsibility for damage caused by improper use or modication of the
interceptor system parts, or claims of loss of prot by a third party.
●The interceptor system is protected by patent.
●Inspect the parts at arrival for damage occurred during transportation.

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
COMPONENTS
The Humphree interceptor system includes one or several control panels, one or several control units, interceptors,
servo units, cables for the complete system, mounting plates (optional), special tools for installing, installation manual,
setup manual, and operator manual.
Control Panel (CP) GPS Antenna RCU
2 x Interceptor Servo Unit
Humphree Wrench (70mm / shaft t) Torque Adater (optional) (36mm /shaft t)
Example Placement of System Components:
Mounting Plate (optional)
Fins Interceptors
RCU
Control Panel

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
MOUNTING GUIDELINES
Make sure to place the interceptors as close to each other as possible, but not closer than 1mm.
IMPORTANT!
The interceptor blades must not hit each other when deployed.
H, HA, HE, and HEA-series X-series
H, HA, HE, and HAE-series
On H, HA, HE & HAE-series, the shaft is positioned 150mm from the lower edge of the interceptor.
150

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
X-Series
On X-Series, the shaft is positioned 120mm from the lower edge of the interceptor.
The shaft can be positioned on either side of the interceptor (X-600 and X-750).
Remove the four screws that secure the shaft sleeve to the interceptor. Pull rmly and the shaft sleeve will come
loose. Move it to the other side and fasten the screws.
Placement on Flat Transom
If the transom is at without an angle, install the interceptor ush to the hull bottom edge.
120
90°

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Placement on Angled Transom
IMPORTANT!
If the transom has an angle, do not place the interceptor flush to the hull bottom.
●It affects the movement of the vessel when the interceptor blade is retracted.
●It causes unnecessary wear on the interceptor.
NOTE!
There is a mounting plate available with a 13° angle adjustment that can be placed flush to the hull bottom.
OPTION 1:
1. Place a board underneath the location of the interceptor.
2. Place the interceptor on the transom and drag it as close as possible to the board.
3. Mark the position of the interceptor.
OPTION 2:
If the angle of the transom is known, place the interceptor according to the table:
xmm
Transom angle (a) Placement above hull bottom (p)
0 0
5 1.5 mm
8 2.5 mm
10 4.5 mm
13 7.5 mm
15 9.5 mm

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Prepare the Transom
Make sure that the transom surface is at.
IMPORTANT!
If the flatness exceeds 1mm, the interceptor may have a higher torque (max 12Nm).
Shaft Sleeve Placement
The shaft sleeve must be installed perpendicular to the interceptor.
If the inside surface has an angle, a spacer (plastic or aluminium) must be produced
to provide a parallel surface.The spacer must be secured to the transom so that it
does not move or glide when the shaft sleeve nut is tightened.
IMPORTANT!
Make sure that the shaft sleeve does not bend during the installation.
1
1
20002000
90°
SHAFT SLEEVE

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
INTERCEPTOR INSTALLATION
Installation without Mounting Plate
NOTE!
See the Installation Drawing for guidance.
Plan the Installation
The preparations suits the following interceptor models:
●Standard (H)
●Extended Asymmetric (HEA)
●X-Series (X)
Tools Needed for the Installation
●Hexagon wrenches (allen keys) 4, 5, and 6mm
●Humphree wrench (included) (70mm / shaft t)
●Humphree torque adapter (optional) (36mm / shaft t)
●Socket 36mm
●Torque wrench
●Hole saw Ø60 (Interceptor shaft) and Ø80mm (control panel)
●Spring scale (for torque measurement)
●Loctite 243
●Marine sealant (sikaex 291)
●Torx T25,T30,T35
●Screw driver PZ2
General Requirements for the Attachment Area
NOTE!
For best performance, the bottom edge of the interceptor must be flush with the hull and no gaps or recesses can
be in front of the extending blade.
Hull shows an internal recess.Make sure to install the
interceptors and servo units
with enough space for service
and maintenance.
If the hull has a sandwich core,
reinforce the area for the mounting
holes and the shaft hole.

12
INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Trial Installation
Before the installation, verify that the interceptor is free to move by
turning the shaft using the included Humphree wrench.
The transom surface must be made at as described in Plan the
Installation.
4. Mark the position of the Ø60 hole.
5. Drill a pilot hole rst.
6. Drill a Ø60 hole with a hole saw for the shaft perpendicular to the
transom.
IMPORTANT!
If the shaft is not perpendicular to the transom, the
interceptor can malfunction.
7. Insert the shaft sleeve into the shaft hole and position the
interceptor in line with the hull bottom. Mark where the passing
bolts are.
8. Remove the interceptor and drill the holes using a 9mm drill. Drill the
holes perpendicular to the transom.
9. Make sure the area on the hull where the O-ring will be located is at and
smooth without scratches.
10. Find a suitable length M8 A4 (AISI 316) stainless steel bolt to secure the
interceptor to the hull. Use a large M8 washer and a nylock M8 stainless
steel nut on the inside.
11. Pre-install the interceptors and check the torque.
12. Position the shaft sleeve’s O-ring in its groove and keep it
in position.
13. Insert the shaft sleeve through the Ø60 hole and
temporary install the M8 bolts for centering/supporting
the interceptor.
NOTE!
Do not apply thread locker (Loctite 243) to the M8 bolts during the trial installation.
14. Tighten the M8 bolts to 10 Nm.
15. Pre-install the shaft sleeve nut.
O-ring
10 Nm

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
16. Tighten the shaft sleeve nut to 16 Nm (9 kg with a spring scale and a
Humphree wrench).
17. Check the shaft torque.
IMPORTANT!
Do not proceed with the trial installation if the
shaft torque exceeds 12Nm. Repeat from Plan the
Installation until the torque is below 12Nm.
18. Use the Humphree wrench and a spring scale to check the
operational torque.
19. Alternatively, push the optional torque adapter onto
the shaft and use a torque wrench with a socket size
36, to check the torque of the shaft.
NOTE!
Make sure that the shaft torque is below 12Nm after the trial
installation before proceeding.

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Final Installation
1. Remove the interceptor.
2. Clean all surfaces properly with soaped water.
IMPORTANT!
Do not clean the parts with acid
or strong detergents. It effects
the strength and lifetime of the
composites and can cause future
malfunction.
3. Sand the lower edge of the interceptor.
a. On the surface facing the transom.
b. On the opposite area of the hull to
improve the adhesion of the sealant.
4. Apply marine sealant (sikaex 291) to the
lower edge of the interceptor.
a. Pre-milled groove for sealant.
b. Gap between the interceptor and mounting plate.
NOTE!
The lower edge gap between the interceptor and the hull must be sealed to achieve maximum water pressure when
the blade extends.
5. Insert the shaft sleeve and make sure that the O-ring is in
position.Apply a layer of marine grease in order to keep it
in position.
6. Apply thread locker (Locktite 243) to the M8 mounting
bolts.
7. Make sure that the lower edge of the interceptor is ush
with the hull bottom.
8. Tighten the M8 bolts to 10 Nm.
Step 4
Step 3
O-ring
10 Nm

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
9. Apply sealant (Sikaex 291 or equivalent) to the surface of the
transom where the shaft sleeve nut will meet.
10. Install the shaft sleeve nut.
11. Tighten the shaft sleeve nut to 16 Nm (9 kg with a spring scale and
a Humphree wrench).
12. Install the second shaft sleeve nut and tighten it to lock the rst
nut.
13. If the space is limited and does not allow the second nut, lock
the rst nut with sealant instead.
14. The sealant, when dried, will lock the nut in position.
IMPORTANT!
Do not proceed with the trial installation if the shaft torque exceeds 12Nm. Repeat from Plan the
Installation until the torque is below 12Nm.
15. Check the operational torque.
a. Use the Humphree wrench and a spring scale.
b. Push the optional torque adapter onto the shaft and use a torque wrench with a socket size 36.
16. Note the measured torque in the WARRANTY FORM.
17. Place the Humphree key on the shaft and rotate the key counter clockwise until
it stops to retract the blade.
18. Retract the blade fully.
19. Proceed to Servo Installation.
DOWN
UP

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Installation with Mounting Plate
NOTE!
See the Installation Drawing for guidance.
Plan the Installation
The preparations suits the following interceptor models:
●Standard (H)
●Extended Asymmetric (HEA)
●X-Series (X)
Tools Needed for the Installation
●Hexagon wrenches (allen keys) 4, 5 and 6 mm
●Humphree wrench (included) (70mm / shaft t)
●Humphree torque adapter (optional) (36mm / shaft t)
●Socket 36mm
●Torque wrench
●Hole saw Ø60 (Interceptor shaft) and Ø80mm (control panel)
●Spring scale (for torque measurement)
●Loctite 243
●Marine sealant (sikaex 291)
●Torx T25,T30,T35
●Screw driver PZ2
General Requirements for the Attachment Area
NOTE!
For best performance, the bottom edge of the interceptor must be flush with the hull and no gaps or recesses can
be in front of the extending blade.
●Install the interceptors and servo units with enough space for service and
maintenance.
●If the hull has a sandwich core, reinforce the area for the mounting holes
and the shaft hole.

17
INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Mounting Plate Installation
The mounting plate can be installed on the hull in four ways: A, B, C, or D.
A. Holes Through the Transom B.Threaded Inserts for GRP Hulls
Most common for GRP Hulls
C. Screws for GRP Hulls. D.Welding a Plate to the Hull
Most common for Aluminium or Steel Hulls
Install Mounting Plate
NOTE!
Steps 1 to 4 must be performed for all options (A, B, C, and D).
1. Secure the mounting plate in the preferred position.
2. Mark the position of the Ø60 hole.
3. Drill a pilot hole rst.
4. Drill a Ø60 hole with a hole saw for the shaft perpendicular to the
transom.
IMPORTANT!
If the shaft is not perpendicular to the transom, the interceptor
can malfunction.

18
INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Option A and B
NOTE!
●For Option A, minimum M8 bolts (AISI 316) is required.
●The mounting plate must be assembled to the transom with countersunk head bolts.
●Do not use cutting or milling uids when drilling the holes in the mounting plate.
●Use the same angle as the bolt head to recess the head and drill the through holes at the same time using a
pillar drill machine. Do not use a hand held machine.
Install the bolts in the marked areas:
NOTE!
Make sure to have done steps 1 to 4 in Install Mounting Plate before proceeding.
1. Drill the bolt holes through the mounting plate.
2. Secure the mounting plate against the transom.
3. Option A: Mark and drill the holes through the hull.
4. Option B: Mark the position and obtain the instructions from the yard engineering ofce for the insert
requirements. For design load of 50 knots, use a load per bolt of 19kN.
5. Remove the mounting plate.
6. Pre-mount the M8 bolts to each M8 stainless steel nut to check if the threads are free from particles.
7. Clean all surfaces properly with soaped water.
Hole area
Hole area

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INSTALLATION MANUAL HCS-5 020311 5.7.x 03
8. Apply marine sealant (Sikaex 291 or equivalent) on the side of the mounting plate so it is facing the transom
and around the drilled holes and bolts.
NOTE!
Make sure to apply sealant uniformly to retain the planarity of the interceptor mounting surface.
Beware of air pockets that can press out the sealant around the edges.
9. Tighten the bolts from the center and out to 12Nm.
IMPORTANT!
Use bolts with a minimum size of M8 and of A4 (AISI
316) stainless steel.
Through-hull holes
Inserts

20
INSTALLATION MANUAL HCS-5 020311 5.7.x 03
Option C
NOTE!
Make sure to have done steps 1 to 4 in Install Mounting Plate before proceeding.
1. Install the mounting plate with BUMAX HARD-FTS ST 6,3x50
screws, drill three (3) holes in a triangle pattern around each
nut inserts in the lower row of the mounting plate.
2. Secure the mounting plate against the transom and drill a 5mm
hole for each BUMAX HARD-FTS ST 6,3x50 screw in the hull.
NOTE!
Insert the BUMAX HARD-FTS ST 6,3x50 screw into a minimum of 13 mm solid GRP material of the hull.
3. Remove the mounting plate.
4. Pre-mount the M8 bolts to each M8 stainless steel nut of the mounting plate to check if the threads are free
from particles.
5. Clean all surfaces properly with soaped water.
6. Apply marine sealant (Sikaex 291 or equivalent) on the side of the mounting plate so it is facing the transom
and around the drilled holes and bolts.
NOTE!
Make sure to apply sealant uniformly to retain the planarity of the Interceptor mounting surface.
Beware of air pockets which can press out the sealant around the edges.