Sonardyne Lodestar 500 User manual

Sonardyne International Limited
Blackbushe Business Park
Yateley, Hampshire
GU46 6G United Kingdom
T. [phone]
F. [phone]
E. [email protected]
W. www.sonardyne.com
UM-8084-6510
User Manual for Lodestar 500
Issue A Rev 1
Issue ate: 27 January 2016

User Manual for Lodestar 500 UM-8084-6510
Issue A Rev 1
ii
© Sonardyne International Limited 2016. All rights reserved.
This user manual is the copyright and intellectual property right of Sonardyne International Limited
(“Sonardyne”) and is provided solely for the customer’s use of the Sonardyne equipment as
described in this user manual and in accordance ith Sonardyne’s then prevailing terms and
conditions of sale. This user manual has been compiled to the best of Sonardyne’s kno ledge and
belief, but no representation, arranty ( hether express or implied) or guarantee is made to any
persons or legal entities as to the accuracy, reliability or completeness of the information contained
in this user manual.
This user manual contains the proprietary, confidential information of Sonardyne and other third
parties and as such may not be used, disclosed or placed in the public domain (by hatever means)
by the customer except expressly in accordance ith and subject to the above referenced terms
and conditions of sale.
The copyright and any and all intellectual property rights of any and all third parties hich may be
referenced in this user manual or hich may have provided proprietary products and/or soft are
and/or documentation (in hatever format) to Sonardyne in respect of the Sonardyne equipment as
described in this user manual are hereby duly ackno ledged. The provision of any and all such
products and/or soft are and/or documentation by Sonardyne shall be subject to and in accordance
ith the relevant third parties’ terms and conditions or the Sonardyne then prevailing conditions of
sale, as appropriate.
The Sonardyne equipment described in this user manual is protected by various UK and US Patents
and other patents internationally and registered trademarks of Sonardyne International Limited.

User Manual for Lodestar 500 UM-8084-6510
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Contacting the Sonardyne Support Team
24-hour Emergency Telephone Helpline: [phone]
The Sonardyne 24-hour helpline is ans ered at the UK Headquarters during normal office hours
(08:00 to 17:00). Outside these hours, your call is automatically transferred to an agency, hich logs
the details of your emergency and alerts the appropriate Sonardyne personnel.
Our aim is to make sure emergency requests are dealt ith immediately during office hours, and are
responded to ithin 30 minutes at all other times.
Please note the helpline is for emergency use only.
If you require non-emergency product support, please contact your nearest Sonardyne office.
Alternatively, contact the Sonardyne Head Office:
Sonardyne International Ltd
Blackbushe Business Park
Yateley
Hampshire
GU46 6GD
United Kingdom
Telephone: [phone]
Fax: [phone]
Email: suppo[email protected]
Note
Email and telephone support is available during normal UK office hours (08:00 to 17:00).

User Manual for Lodestar 500 UM-8084-6510
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Contents
Contacting the Sonardyne Support Team .................................................................................. iii
Amendment History .................................................................................................................... vii
Section 1 – Introduction ............................................................................................................... 1
1.1 Scope of this Manual ............................................................................................................. 1
1.2 Purpose of this Manual .......................................................................................................... 1
1.3 U.S. Department of Commerce License ................................................................................. 1
1.4 Related Publications .............................................................................................................. 1
Section 2 – Safety ......................................................................................................................... 2
2.1 Introduction ............................................................................................................................ 2
2.2 Safety Procedures ................................................................................................................. 2
2.2.1 Warnings .................................................................................................................. 2
2.2.2 Cautions ................................................................................................................... 3
Section 3 – Technical escription ............................................................................................... 4
3.1 Introduction ............................................................................................................................ 4
3.2 Physical Layout ..................................................................................................................... 5
3.3 Po er .................................................................................................................................... 5
3.4 Po er Pass Through ............................................................................................................. 5
3.5 Battery ................................................................................................................................... 6
3.6 Connector Ports ..................................................................................................................... 6
3.6.1 CP/E1 Pin out Functions .......................................................................................... 7
3.6.2 C1 Pin out Functions ................................................................................................ 7
3.6.3 T1/T2 Pin out Functions ........................................................................................... 8
3.6.4 Trigger Input............................................................................................................. 8
3.7 Pressure Relief Vent Valve .................................................................................................... 9
Section 4 – Installation ............................................................................................................... 10
4.1 Introduction .......................................................................................................................... 10
4.2 Unpacking and Inspecting .................................................................................................... 10
4.3 Installation Location ............................................................................................................. 10
4.4 Mounting .............................................................................................................................. 11
4.4.1 Site Preparation ..................................................................................................... 11
4.4.2 Mounting Holes and Do els ................................................................................... 11
4.5 Vehicle Alignment ................................................................................................................ 12
4.6 Preparing the Lodestar 500 for use ...................................................................................... 12
4.6.1 Checking the Pressure Relief Vent Valve ............................................................... 13
4.6.2 Checking Communications ith the Lodestar ......................................................... 13
Section 5 – Operation ................................................................................................................. 14
5.1 Introduction .......................................................................................................................... 14
5.2 AHRS Operation .................................................................................................................. 14
5.3 SPRINT INS Operation ........................................................................................................ 14
5.4 After Use ............................................................................................................................. 14

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Section 6 – Retrieval and Storage ............................................................................................. 15
6.1 Introduction .......................................................................................................................... 15
6.2 Retrieval .............................................................................................................................. 15
6.3 Storage ................................................................................................................................ 15
Section 7 – Maintenance ............................................................................................................ 16
7.1 Introduction .......................................................................................................................... 16
7.2 Retrieval from the Water ...................................................................................................... 16
7.3 Dismantling .......................................................................................................................... 16
7.4 Cleaning .............................................................................................................................. 16
7.5 Inspecting ............................................................................................................................ 16
7.6 Lubricating ........................................................................................................................... 16
7.6.1 Connectors ............................................................................................................ 16
7.7 Corrosion ............................................................................................................................. 16
7.8 Recalibration ........................................................................................................................ 17
Section 8 – Firmware Update ..................................................................................................... 18
8.1 Introduction .......................................................................................................................... 18
8.2 Updating the Firm are......................................................................................................... 18
8.2.1 Pre-requisites ......................................................................................................... 18
8.2.2 Update Procedure .................................................................................................. 18
Section 9 – Lodestar Messages Specification .......................................................................... 22
9.1 AHRS Messages ................................................................................................................. 22
9.2 SPRINT INS Operation ........................................................................................................ 22
Section 10 – Troubleshooting .................................................................................................... 23
10.1 Introduction .......................................................................................................................... 23
10.2 Lodestar Hard are Test Procedure ..................................................................................... 23
10.3 Recovery Procedures .......................................................................................................... 25
10.3.1 Lodestar Hard are Reset ...................................................................................... 25
10.3.2 Restore Lodestar Factory Settings ......................................................................... 25
Section 11 – Spares .................................................................................................................... 27
11.1 Introduction .......................................................................................................................... 27
11.2 Lodestar 500 Spares List ..................................................................................................... 27
Section 12 – Technical Specifications....................................................................................... 28
12.1 Technical Dra ing ............................................................................................................... 28
12.2 Specifications ...................................................................................................................... 28
12.2.1 Performance .......................................................................................................... 28
12.2.2 Electrical ................................................................................................................ 29
12.2.3 Environmental ........................................................................................................ 29
12.2.4 Mechanical ............................................................................................................. 29
efinitions 30
Figures
Figure 3-1 Lodestar 500 Layout ..................................................................................................... 5

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Figure 3-2 Lodestar 500 Connect Ports ......................................................................................... 6
Figure 3-7 Pressure Relief Vent Valve ........................................................................................... 9
Figure 4-1 Lodestar 500 Mounting and Alignment ........................................................................ 11
Figure 4-2 Endcap Alignment Markings ....................................................................................... 12
Figure 10-1 Lodestar Hard are Test Procedure .......................................................................... 24
Figure 12-1 Lodestar Outline Dimensions (mm) ........................................................................... 28
Tables
Table 1-1 Related Publications ...................................................................................................... 1
Table 3-1 Lodestar 500 Connector Port Functions ......................................................................... 6
Table 3-2 Lodestar 500 CP/E1 Pin Out .......................................................................................... 7
Table 3-3 Lodestar 500 C1 Pin Out ................................................................................................ 7
Table 3-4 Lodestar 500 T1/T2 Pin Out ........................................................................................... 8
Table 3-5 Lodestar 500 Trigger Input ............................................................................................. 8
Table 6-1 Storage Conditions ...................................................................................................... 15

User Manual for Lodestar 500 UM-8084-6510
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Amendment History
The amendment history records all amendments and additions made to this manual.
Issue Revision ate Comments Section Page
A 1 27/01/16 Initial Issue All All

Section 1 – Introduction 1
Section 1 – Introduction
1.1 Scope of this Manual
This user manual defines the safe installation, operation and maintenance of the Type 8084-6510
Lodestar AHRS / SPRINT INS hard are. Where applicable, the manual ill refer the reader to
related publications covering operation as an Attitude and Heading Reference System (AHRS) or
SPRINT Inertial Navigation System (SPRINT).
1.2 Purpose of this Manual
This user manual contains information for anyone involved in Lodestar and INS system operations.
This manual includes technical information to configure, operate and maintain Lodestar AHRS and
specific information concerning Lodestar inertial systems supplied by Sonardyne.
To make sure the safety of the installer and operator is maintained it is important that all arnings
and cautions in Section 2 –Safety of this manual and in any additional manuals are read and fully
understood.
1.3 U.S. epartment of Commerce License
This product contains U.S. Department of Commerce controlled items. As such the Lodestar 500, or
Lodestar portion of the product, must not be removed from the housing, be disassembled or
repaired, outside of the terms and conditions detailed in the U.S. Department of Commerce Re-
Export Licence under hich the product as sold. If any servicing or repair of the Seanet Lodestar,
or Lodestar portion of the product is required, consult your nearest Sonardyne office for advice.
1.4 Related Publications
To make sure the equipment is operated safely, a Sonardyne Safety Manual is supplied ith this
user manual. It is important that the Sonardyne Safety Manual is read and fully understood before
proceeding ith any activity on the equipment.
Table 1-1 Related Publications
Publication Title
Sonardyne Safety Manual Operational and Safety Precautions
UM-8253 User Manual for SPRINT
UM-8 84-1 7 Lodestar AHRS Operation Manual
UM-8 84-1 9 Lodestar AHRS Messages

Section 2 – Safety 2
Section 2 – Safety
2.1 Introduction
Before any activity is carried out on the equipment, it is recommended that the included Sonardyne
Safety Manual and all arnings and cautions in this manual are read and fully understood.
It is recommended that the operator complies ith the Health and Safety Regulations applicable to
the vehicle and the region before operating this equipment.
Operators and service personnel must be familiar ith the normal operating and safety procedures
for the subsea equipment being operated.
Documentation must be consulted henever a or arning symbol is found on the
equipment, in order to determine the nature of the potential hazard and any actions hich must be
taken.
If any additional equipment is used, any arnings and cautions in the equipment user manual must
be read and fully understood.
If the equipment is used in a manner not specified by the manufacturer, the protection provided by
the equipment may be impaired.
The safety of any system incorporating this equipment is the responsibility of the assembler of the
system.
2.2 Safety Procedures
2.2.1 Warnings
Personal protection. Appropriate protective equipment such as protective footwear, hard hat
and gloves must be worn when handling or carrying out any procedures involving Sonardyne and
other equipment
Heavy equipment. Many Sonardyne products and equipment types, such as Lodestar,
transponders, transceivers, cable drums etc. require Manual Handling Equipment (MHE) for lifting due
to their heavy weight. If MHE is not available, it is the responsibility of the operator to perform a
manual handling risk assessment prior to carrying out manual lifting/handling. Refer to the individual
equipment documentation for weight specifications.
ismanting. This instrument must only be accessed internally and dismantled by qualified
Sonardyne personnel.
Lithium-ion Battery Pack. This instrument contains a backup lithium-ion battery pack. Refer to
the Sonardyne Safety Manual for saftey information for lithium-ion batteries.
Risk of toxic gases and Corrosive Liquids. o not stand in direct line with the end of the unit
when operating the Pressure Relief Vent Valve. Sudden release of high pressure gases could cause
injury to personnel. Wear Personal Protective Equipment such as goggles when operating the
Pressure Relief Vent Valve.

Section 2 – Safety 3
2.2.2 Cautions
Incorrect Power Supply. Make sure the Lodestar is supplied with 20 V C to 50 V C. o not use
an AC power supply.
amage to connectors. Failure to clean sand or silt correctly could result in damage to the
connectors and O-ring seals.

Section 3 – Technical Description 4
Section 3 – Technical escription
3.1 Introduction
Sonardyne International Limited has applied its comprehensive experience in producing advanced
and dependable marine solutions to the development of the Lodestar Attitude and Heading
Reference System (AHRS) / Inertial Navigation System (INS).
The Lodestar is a solid state AHRS/INS that includes three Ring Laser Gyroscopes (RLGs) and
three linear accelerometers. These inertial-grade components provide ra data to the Sonardyne-
developed gyrocompass algorithm, hich uses them to produce a full range of accurate real-time
motion and attitude measurements in all sea states.
Developed originally to provide accurate heading and attitude measurements for Sonardyne’s family
of acoustic positioning systems, Lodestar is equally suited to a variety of other applications here
the accuracy of heading and attitude measurements is of critical importance. Lodestar can operate
either as a stand-alone AHRS or as part of an integrated system.
The Lodestar 500 provides the follo ing as standard:
• Industry standard output telegrams
• Battery backup to maintain uninterrupted operation in the event of brief po er failure
• 8 GB of internal memory.
• Upgrade capability to a full INS that provides additional outputs of position, velocity,
orientation and angular velocity at high update rates.
• 0.04° (dynamic) to 0.1° secant-latitude.
• 0.01° roll and pitch measurement accuracy.
• Fast follo -up speed of >500° per second.
• A settling time of less than five minutes.
• Support for all industry standard telegrams.
• MTBF inertial sensors (RLG and Accelerometer) > 400,000 hours
• Flexible mounting arrangements
• Heave measurement accuracy the greater of 5 cm or 5% of measured heave.
• Robust heave algorithm.
• Data output through RS232 serial, RS485 serial or Ethernet interfaces.
The Lodestar 500 has undergone independent and exhaustive testing against an industry-
recognised reference and has proved capable of delivering accurate measurements in highly
dynamic marine environments.
Lodestar 500 benefits from Sonardyne’s orld-class manufacturing, support and training
organisation, hich has a ell-established record for providing trusted solutions.

Section 3 – Technical Description 5
3.2 Physical Layout
The 8084-6510 Lodestar 500 is sho n in Figure 3-1.
Figure 3-1 Lodestar 500 Layout
3.3 Power
The Lodestar is po ered from an external 20V to 50V DC po er supply through the CP port.
A po er supply is not provided ith the Lodestar 500. Refer to Section 12 – Technical
Specifications for po er requirements.
3.4 Power Pass Through
The Lodestar is capable of passing through input po er (20V to 50V DC from an external po er
supply) to sensors connected to the Lodestar’s C1, T1 and T2 ports. Refer to SPRINT User Manual
UM-8253 for operational use.

Section 3 – Technical Description 6
3.5 Battery
The Lodestar contains a backup lithium-ion battery to cope ith short external po er interruptions
and has a life of approximately five minutes ith no external po er. The battery is charged from the
external po er supply and hen depleted, takes approximately 20 minutes to reach full charge.
3.6 Connector Ports
The Lodestar 500 is provided ith 4 x Seacon connector ports as sho n in Figure 3-2. The
connector port functions are described in Table 3-1.
Figure 3-2 Lodestar 500 Connect Ports
Table 3-1 Lodestar 500 Connector Port Functions
Lodestar 500 Port Function
CP/E1 RS232 and RS485 Full Duplex Communications and Input Po er
Ethernet (100 Mbit/s) Communications and Input Trigger
C1 RS232 Communications, Input Trigger and Po er Pass Through
T1 RS232 and RS485 Half Duplex Communications, Output Trigger and Po er
Pass Through
T2 RS232 and RS485 Half Duplex Communications, Output Trigger and Po er
Pass Through

Section 3 – Technical Description 7
3.6.1 CP/E1 Pin out Functions
The Lodestar 500 CP/E1 connector pin functions are sho n in Table 3-2.
Table 3-2 Lodestar 500 CP/E1 Pin Out
Seacon Pin No. Function Connection
1 DC 0V Black Socket
2 DC In Red Socket
3 0V1 RS232 & RS485 Pin 5
4 Screen
6 Trigger In BNC Inner
7 Ethernet TD - Pin 6
8 RS232/485 Select Connect to 0V1 for RS232 / Not
connected for RS485
10 Ethernet RD - Pin 2
11 RX TX+ RS232 & RS485 Pin 3
12 Ethernet TD + Pin 3
13 TX TX - RS232 Pin 2 / RS485 Pin 4
14 RX - RS485 Pin 1
15 Ethernet RD + Pin 1
16 RX + RS485 Pin 2
3.6.2 C1 Pin out Functions
The Lodestar 500 C1 connector pin functions are sho n in Table 3-3.
Table 3-3 Lodestar 500 C1 Pin Out
Seacon Pin No. Function Connection
2 0V1 RS232 = Pin 5
BNC Inner
3 Trigger 0v BNC Outer
4 DC 0V Black Socket
5 TX TX- RS232 = Pin 2
6 RX TX+ RS232 = Pin 3
7 DC Out Red Socket

Section 3 – Technical Description 8
3.6.3 T1/T2 Pin out Functions
The Lodestar 500 CP/E1 connector pin functions are sho n in Table 3-4.
Table 3-4 Lodestar 500 T1/T2 Pin Out
Seacon Pin No. Function Connection
2 0V1 RS232 & RS485 = Pin 5
BNC Inner
3 Trigger 0v BNC Outer
4 DC 0V Black Socket
5 TX TX- RS232 = Pin 2 RS485 = Pin 4
6 RX TX+ RS232 & RS485 = Pin 3
7 DC Out Red Socket
3.6.4 Trigger Input
The Lodestar trigger input characteristics are sho n in Table 3-5.
Table 3-5 Lodestar 500 Trigger Input
Parameter Specification
Voltage Recommended 0 V->5 V
Minimum 0 V->3.6 V
Pulse Width Recommended 10 ms
Minimum 5 µs

Section 3 – Technical Description 9
3.7 Pressure Relief Vent Valve
A Pressure Relief Vent Valve is provided to stop a build-up of gas inside the transponder caused by
the charging process or a failing battery.
The Pressure Relief Vent Valve must be checked before installing and operating the Seanet
Lodestar; refer to Section 4.6.1 “Checking the Pressure Relief Vent Valve”.
Figure 3-3 Pressure Relief Vent Valve
Pressure Relief Vent Valve

Section 4 – Installation 10
Section 4 – Installation
4.1 Introduction
Before installing the equipment, make sure Section 2 – Safety is read and fully understood.
This section explains ho to install the Seanet Lodestar before deploying.
4.2 Unpacking and Inspecting
The Lodestar AHRS includes a number of delicate and sensitive electronic components. In
particular, the accelerometers and RLGs that form the Inertial Measurement Unit (IMU) are sensitive
to shock and vibration. If damaged, these components cannot be replaced in the field, and the
complete Lodestar unit must be returned to the factory for repair and recalibration.
Note
Always handle the Lodestar with care. Store the unit in the shipping container until it is ready to
be installed in the prepared location.
Inspect the Lodestar and all the supplied parts on receipt and check the shipment includes all the
items listed on the shipping documents. Inform Sonardyne immediately if there are any parts
missing, or if any of the supplied parts sho signs of damage.
4.3 Installation Location
The Lodestar 500 can be installed at any convenient location on the vehicle. Ho ever, to gain
optimal performance from the system, identify a location to install the Lodestar 500 that conforms as
closely as possible to the follo ing criteria:
• If possible, the location should be close to the vehicle centre of rotation under normal
operating conditions.
• The location must not be subject to excessive vibration or impulse shock.
• The location must not exceed the environmental limits for temperature defined in Section
12.2.3 “Environmental”.
• The location must provide a mounting surface that is of sufficient strength to support the
Lodestar 500’s eight safely and ithout flexing.
• The location must provide access for po er and communication connections.
• There must be sufficient space to allo easy access to install the Lodestar 500.
• Do not store tools, equipment or chemicals here they can damage the Lodestar 500 or
the connection cables.
• Make sure the Lodestar 500 and its connection cables do not cause an obstruction to
personnel operating in the area.
• Do not use a location here the connection cables are likely to suffer damage from
mechanical stresses or chemical attack.

Section 4 – Installation 11
4.4 Mounting
4.4.1 Site Preparation
The Lodestar 500 can be installed in any convenient orientation ith respect to the vessel’s body
frame. You can compensate for any misalignment bet een the Lodestar 500 and the vessel by
carefully measuring the mounting angles and entering them in the AHRS or SPRINT soft are; refer
to Section 4.5 “Vehicle Alignment”.
4.4.2 Mounting Holes and owels
The subsea Lodestar has a set of eight mounting holes on the underside of the unit. In addition
there are t o sets of three-do el alignment holes and four alignment flats. The mounting holes,
do el alignment holes and alignment flats are sho n in Figure 4-1.
Note
The forward direction is UP in Figure 4-1.
Figure 4-1 Lodestar 500 Mounting and Alignment

Section 4 – Installation 12
4.5 Vehicle Alignment
The Lodestar 500’s nominal alignment to the vehicle frame (FWD and STBD) is engraved on the top
endcap as sho n in Figure 4-2.
Figure 4-2 Endcap Alignment Markings
FWD and STBD Endcap Alignment Markings
Four flats machined into the base plate serve as alignment references.
If it is not possible to mount the Lodestar 500 ithin the limits described above for coarse alignment
or if you ish to mount the Lodestar at other angles ith respect to the reference axes on the
vessel, ROV or platform, the mounting angles must be measured and configured on the Lodestar
500.
The Lodestar can be configured for any mounting angle that may be required.
An in-depth description of the theory and process for measuring and configuring mounting angles
can be found in the follo ing user manuals:
• UM-8253 “User Manual for SPRINT”
• UM-8 84-1 7 “Lodestar AHRS Operation Manual”
These manuals also include an explanation for the effects of misalignments bet een the vehicle
and the Lodestar.
4.6 Preparing the Lodestar 500 for use
The follo ing checks and procedures must be carried out to make sure the Lodestar 500 is
serviceable and ready for use:
• Check the Pressure Relief Vent Valve; refer to Section 4.6.1 “Checking the Pressure
Relief Vent Valve”.
• Secure the Seacon Cables and fit the Seacon connector covers to all unused connector
ports.
• Check communications ith the Lodestar; refer to Section 4.6.2 “Checking
Communications with the Lodestar”.

Section 4 – Installation 13
4.6.1 Checking the Pressure Relief Vent Valve
Check the Pressure Relief Vent Valve is flush ith the endcap. If the Pressure Relief Vent Valve is
not flush it could indicate a pressure build-up during previous operations due to a fault developing in
the backup battery pack.
Pressure Relief Vent Valve
To operate the Pressure Relief Vent Valve:
Note
Refer to Warnings in Section 2 – Safety “Risk of toxic gases and corrosive liquids”.
1. Scre an M4 bolt into the Pressure Relief Vent Valve.
2. Slo ly pull the M4 bolt to ithdra the vent valve.
3. To close the vent valve, remove the M4 bolt and carefully push the valve in until it is flush ith
the endcap face.
4.6.2 Checking Communications with the Lodestar
Check communications ith the Lodestar using the AHRS or SPRINT soft are; refer to UM-8 84-
1 7 “Lodestar AHRS Operation Manual” or UM-8253 “User Manual for SPRINT”.