Klein Marine Systems, Inc. HydroChart 5000 User manual

HYDROCHART 5000 SONAR
SYSTEM
Operations and Maintenance Manual
P/N 11210080, Rev. 02
11 Klein Drive
Salem, NH 03079-1249
U.S.A.
Tel: [phone]
Fax: [phone]
www.KleinMarineSystems.com

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\HydroChart 5000 Sonar Operations and Maintenance Manual P/N 11210080, Rev. 02
This document contains proprietary information, and such information may not be
disclosed to others for any purpose or used for any manufacturing purpose without
expressed written permission from Klein Marine Systems, Inc. (KMS). The
information provided is for informational purposes only and is subject to change
without notice. KMS assumes no responsibility or liability for any errors,
inaccuracies or omissions that may be present in this document.
The SonarPro software program may be used or copied only in accordance with
the terms of the Software License Agreement.
©Copyright 2010–2019 by Klein Marine Systems, Inc. All rights reserved.
SonarPro®is a registered trademark of Klein Marine Systems, Inc.
Intel®and Pentium®are registered trademarks of Intel Corporation.
Windows®is a registered trademark of Microsoft Corporation.
vxWorks®is a registered trademark of Wind River Systems, Inc.
Kevlar®is a registered trademark of the DuPont Company.

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WARNING
Klein Marine Systems recommends all troubleshooting be done by
a trained technician. Some circuits in the Transceiver and
Processing Unit (TPU) have voltages as high as 240 volts, and
some circuits in the sonar Sonar Head Unit have 1500 volts. You
should familiarize yourself with the location of these voltages
before you attempt any troubleshooting. Failure to observe these
warnings could result in injuries to personnel.
CAUTION
Serious damage to the sonar electronics may occur if the Sonar
Head Unit is operated out of the water for periods longer than
15 minutes. Let the sonar cool 15 minutes or longer between
operations. Protect the Sonar Head Unit from direct exposure to the
sun prior to and during operation in high temperature climates.
CAUTION
The depth rating on the transducers is 200 meters (656 feet).
Operations at depths greater than 200 meters may damage the
transducers.

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HydroChart 5000 Sonar Operations and Maintenance Manual P/N 11210080, Rev. 02
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Sonar System Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
What Is Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Conditions Of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Changes, Errors And Omissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Software License Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
What’s in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi
Note, Warning, Caution, and Shock Hazard Notices . . . . . . . . . . . . . xvii
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
CHAPTER 1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.1 Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.2 TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.3 SonarPro Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.4 Deck Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Surface Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Subsurface Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.1 Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.2 TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
CHAPTER 2: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Sonar System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Topside System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 System Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.2 TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.3 SonarPro Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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2.3 Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.2 Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.3 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.4 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.5 A/D Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.6 Multiplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.7 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.8 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 SonarPro Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Deck Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6.1 Sound Velocity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6.2 Motion Reference Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CHAPTER 3: Preparation for Deployment . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Unpacking the TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Unpacking the SonarPro Workstation . . . . . . . . . . . . . . . . . . 3-2
3.1.3 Unpacking the Sonar Head Unit and Deck Cable . . . . . . . . . 3-2
3.2 Locating the Topside System Components . . . . . . . . . . . . . . . . 3-2
3.3 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.2 TPU and SonarPro Workstation Circuit Breakers . . . . . . . . . 3-3
3.4 Sonar Head Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Motion Reference Unit Installation . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Topside System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6.1 TPU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6.2 SonarPro Workstation Connections . . . . . . . . . . . . . . . . . . . . 3-8
3.7 Connecting the Topside System Components . . . . . . . . . . . . . . 3-8
3.8 Topside System Controls and Indicators . . . . . . . . . . . . . . . . . 3-11
3.8.1 TPU Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.8.2 SonarPro Workstation Controls and Indicators . . . . . . . . . . 3-13

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HydroChart 5000 Sonar Operations and Maintenance Manual P/N 11210080, Rev. 02
3.9 Predeployment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.10 Bathymetric System Calibration and Patch Test . . . . . . . . . . . 3-15
3.10.1 Static Position Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.10.2 Latency Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.10.3 Pitch Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.10.4 Yaw Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.10.5 Roll Bias Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
CHAPTER 4: Equipment Maintenance . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Maintenance General Comments . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Maintenance Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.1 Daily Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.2 Weekly Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.3 Long Term Maintenance Checklist . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Disassembling and Reassembling the Sonar Head Unit . . . . . . 4-3
4.3.1 Disassembling the Sonar Head Unit . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Reassembling the Sonar Head Unit . . . . . . . . . . . . . . . . . . . 4-10
APPENDIX A: General Setup, Configuration and
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Basic System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.2 Basic System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.3 Installing SonarPro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.4 Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.4.1 Checking the Telemetry Link to the Sonar Head Unit . . . . . A-4
A.4.2 Checking the Transmitters before Deployment . . . . . . . . . . A-4
A.4.3 Checking the Receivers before Deployment . . . . . . . . . . . . A-5
A.4.4 Setting up for Testing the Electronics . . . . . . . . . . . . . . . . . A-5
A.4.5 Checking the Multiplexer Board . . . . . . . . . . . . . . . . . . . . . A-5
A.4.6 Checking the Transmitter Board . . . . . . . . . . . . . . . . . . . . . A-7
A.4.7 Checking the Receiver Boards . . . . . . . . . . . . . . . . . . . . . . . A-8
A.4.8 Sonar Head Unit Power Supply Pinouts . . . . . . . . . . . . . . . . A-8
A.5 Spare Boards and Components . . . . . . . . . . . . . . . . . . . . . . . . A-9

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A.6 Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
A.7 NMEA 0183 Formats and Information . . . . . . . . . . . . . . . . . A-10
APPENDIX B: Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

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List of Figures
Figure 1-1: HydroChart 5000 Sonar System Topside System Main Components . . . . . . 1-4
Figure 1-2: HydroChart 5000 Sonar System Sonar Head Unit . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-3: HydroChart 5000 Sonar System Sonar Head Unit Block Diagram . . . . . . . 1-7
Figure 1-4: Deck Cable Connector—at Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-5: HydroChart 5000 Sonar System TPU Electronics Block Diagram . . . . . . . 1-9
Figure 1-6: HydroChart 5000 Sonar System TPU Electronics Chassis . . . . . . . . . . . . 1-10
Figure 3-1: Sonar Head Unit Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-2: FWD and Arrow Labels on the Sonar Head Unit Mounting Flange . . . . . . 3-4
Figure 3-3: Sonar Head Unit Eye Rings and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-4: TPU Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-5: SonarPro Workstation Back Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-6: TPU Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-7: SonarPro Workstation Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 4-1: Removing the Phillips Head Screws from the Top of the Fairing . . . . . . . . 4-3
Figure 4-2: Removing the Skid Plates from the Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-3: Removing the Phillips Head Screws from the Bottom of the Fairing . . . . . . 4-4
Figure 4-4: Removing the Socket Head Cap Screws that Secure the Transducers to the
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-5: Fairing Halves Separated from the Frame . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-6: Disconnecting the Cables from the Sonar Electronics End Cap . . . . . . . . . 4-6
Figure 4-7: Sonar Electronics Housing with all the Cables Disconnected . . . . . . . . . . . 4-6
Figure 4-8: Removing the Altimeter Transducer from the Frame . . . . . . . . . . . . . . . . . . 4-7
Figure 4-9: Removing the Socket Head Cap Screw that Secures the Sonar Electronics
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-10: Sliding the Sonar Electronics Housing out of the Frame . . . . . . . . . . . . . . . 4-8
Figure 4-11: Sonar Head Unit Fully Disassembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-12: Tightening the Socket Head Cap Screws in the Electronics Housing
Connector End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

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Figure 4-13: Inserting the 7-inch, 1/2 x 13 threaded rod into the Connector End cap . . . 4-9
Figure 4-14: Pulling the Sonar Electronics Chassis out of the Sonar Electronics
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-15: Aligning and Installing the Connector End Cap . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-16: Sonar Electronics Chassis Installed in Frame with the Jumper and
Altimeter Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-17: Sonar Electronics Housing Connector End Cap Connectors . . . . . . . . . . 4-12
Figure 4-18: Sonar Head Unit Fully Assembled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Figure A-1: HydroChart 5000 Sonar System Basic System Setup Diagram . . . . . . . . . . A-3
Figure A-2: Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Figure A-3: Transmit Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Figure A-4: Image in Sonar Viewer Window During a Rub Test . . . . . . . . . . . . . . . . . . A-6
Figure A-5: Multiplexer Board Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Figure A-6: Sample Transmit Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Figure A-7: The Sonar Head Unit Power Supply Pinouts . . . . . . . . . . . . . . . . . . . . . . . . A-8
Figure A-8: Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

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HydroChart 5000 Sonar Operations and Maintenance Manual P/N 11210080, Rev. 02
List of Tables
Table 1-1: Deck Cable Connector—Sonar Head Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 3-1: TPU Power Cable Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table A-1: TPU Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Table A-2: Sonar Head Unit Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Table B-1: List of Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1