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rapidCAST User’s Guide

March 2018

EAR-Controlled Technology Subject to Restrictions Contained on the Cover Page.

Page

Figure 12.

Removing the Winch Assembly Covers

Figure 13.

Winch Assembly Connectors

To Connect the Cables:
1. Route all five (5) cables through the cable routing hole. Ensure that the cables do not interfere

with the motion of the spool, LevelWind, or tension arm.

2. Connect the Motor Driver cable between the Control Module and Winch. The Motor Driver con-

nector is located under the motor side cover on top of the motor.

3. Connect the Spool cable between the Control Module and Winch. The Spool connector is located

under the belt side cover.

Summary of Contents for rapidCAST

Page 1: ...license license exception or other approval from the appropriate U S Government agency before being exported from the United States or provided to any foreign person Diversion contrary to U S law is...

Page 2: ...he rapidCAST System 25 Environmental Conditions 25 Lifting the RapidCAST System 26 Installing the Pipe Mount 27 Installing the Winch on the Pipe Mount 28 Installing the Control Module 29 Line Properti...

Page 3: ...assembling the Spool Module 81 APPENDIX A INSTALLATION DRAWINGS 83 LIST OF FIGURES Figure 1 Winch Assembly Overview 4 Figure 2 Interface Module Overview 4 Figure 3 Control Module Overview 5 Figure 4 P...

Page 4: ...ion 42 Figure 34 Launch Position 43 Figure 35 Recovery Position 44 Figure 36 Workspace Files 45 Figure 37 Packing the Winch 60 Figure 38 Winch Configuration Settings 61 Figure 39 Tension Arm Calibrati...

Page 5: ...Added instructions for Disassembly and Packing Added the outline installation drawings to Appendix A October 2016 Added Replacing the Spool to the maintenance procedures Updated the tension arm calibr...

Page 6: ...Page vi EAR Controlled Technology Subject to Restrictions Contained on the Cover Page NOTES...

Page 7: ...this documentation to maximize your user experience T E C H N I C A L S U P P O R T If you have technical issues or questions involving a specific application or deployment contact Phone 1 858 842 260...

Page 8: ...ng an automated Bluetooth connection rapidCAST provides A Tension Control System that allows the probe to fall freely under the influence of gravity even when the probe is tethered to the winch Line t...

Page 9: ...trictions Contained on the Cover Page Page 3 rapidCAST Overview T H E R A P I D C A S T O V E R V I E W I N C L U D E S T H E F O L L O W I N G Terminology Mechanical Requirements Electrical Requireme...

Page 10: ...e 4 EAR Controlled Technology Subject to Restrictions Contained on the Cover Page Terminology Use this section to learn the terms that will be used throughout the manual Figure 1 Winch Assembly Overvi...

Page 11: ...ectors are latching non threaded push pull types The Control and Antenna connectors are threaded and screw on Ensure that connectors are fully seated otherwise water re sistance may be compromised Con...

Page 12: ...ic control module to the survey PC is re quired As the probe uses wireless Bluetooth telemetry no cabling is required for data download The figure below depicts mounting and cable clearance requiremen...

Page 13: ...R Controlled Technology Subject to Restrictions Contained on the Cover Page Page 7 Figure 5 Cable Clearance Requirements Figure 6 Mounting Requirements See Appendix A Installation Drawings for a detai...

Page 14: ...of the line in the ship propel ler The maximum profile depth is then limited by the amount of line on the rapidCAST spool and the probe pressure rating of 2000m Line Type Hollow Spectra line of 500lb...

Page 15: ...ject to Restrictions Contained on the Cover Page Page 9 Power Cable Connections The diagram below shows how the power cables may be connected Figure 7 Power Cable Connections Figure 8 7000625 Cable Pl...

Page 16: ...arch 2018 rapidCAST User s Guide Page 10 EAR Controlled Technology Subject to Restrictions Contained on the Cover Page Figure 10 7000652 Cable Plug Termination Figure 11 Vessel Socket Receptacle Outle...

Page 17: ...ess Steel Control Module Weight 14kg 30 86 lbs Length 52cm 20 47 Width 34cm 13 34 Height 29cm 11 42 Input Power 90 264 VAC 47 63 Hz Output Power 48 VDC Davit Length 160cm 63 Diameter 5cm 2 Weight 1 18...

Page 18: ...which 1700 meters can be used for normal operation see Line Properties page 30 Typically only 1200 meters of line are used Deployments less than 100 meters deep The buoyancy tailspool can be used In...

Page 19: ...echnology Subject to Restrictions Contained on the Cover Page Page 13 Quick Review Check that you know the Terminology used Reference Figure 1 through Figure 4 Check that the boat meets the Mechanical...

Page 20: ...ed on the Cover Page Installation I N S T A L L A T I O N I N C L U D E S T H E F O L L O W I N G S T E P S Unpacking the rapidCAST system Installing the RapidCAST Control Software Learning Cable Conn...

Page 21: ...LLEY 1 ea 9002209 SHOULDER STRAP DAVIT CASE RCAST 1 ea 6001754 CASE TRANSIT RCAST CONTROL MODULE 6001427 ASSY CONTROL MODULE RAPIDCAST 1 ea 6001432 ASSY INTERFACE MODULE RAPIDCAST 1 ea 8000592 MOUNT P...

Page 22: ...oftware is located on the documentation CD To install the drivers and software 1 Connect the system and apply power Connect the PC to the Control USB port of RapidCAST In terface Module which should a...

Page 23: ...u item will be red If there is a compatibility mismatch the system should not be operated and the software needs to be upgraded or downgraded until their Compatibility Groups match A Tour of the Rapid...

Page 24: ...oximation Line length is measured relative to the encoder zero position home It may be negative if the winch has rotated inward relative to zero Driver Temp Displays the temperature of the motor contr...

Page 25: ...Route all five 5 cables through the cable routing hole Ensure that the cables do not interfere with the motion of the spool LevelWind or tension arm 2 Connect the Motor Driver cable between the Contro...

Page 26: ...le between the Control Module and Interface Module 8 Connect the Antenna cable between the Control Module and Interface Module Connect the Patch antenna to the Control Module larger vessels use Figure...

Page 27: ...rapidCAST User s Guide March 2018 EAR Controlled Technology Subject to Restrictions Contained on the Cover Page Page 21 Figure 15 rapidCAST Cable Connections Small Vessels...

Page 28: ...han 10 meters See Figure 15 for cable connections The antenna is Omni directional the best reception is around the antenna in a doughnut shape do not orientate the antenna by pointing the tip of the a...

Page 29: ...hen the switch is in PC Control position the Activity light will flash two rapid blinks and then 1 second off Local Control position the Activity light will flash three rapid blinks and then 1 second...

Page 30: ...Emergency Stop is pressed or the Control Cable is disconnected ACTIVITY LED GREEN Indicates the state of the Motor Driver Slow Blink 1 Sec On 1 Sec Off The Motor Driver is powered but is not yet ready...

Page 31: ...eration of the environmental conditions The radiative heat from the sun and ship deck can cause ambient shipboard temperatures to exceed 40 C When operating in a hot environment the following items sh...

Page 32: ...ot load bearing and could be damaged if it is used as a lifting point The system should be lifted by any of the four 4 handles available on the covers If the covers are re moved the system can be lift...

Page 33: ...mount the Pipe Mount PN 8000592 An adapter is available from Oceanscience that will facilitate the installation of a RapidCAST where an Underway CTD was previously installed One such adapter is shown...

Page 34: ...ng and then rotating Slide the winch on to the pipe mount and rotate the winch back and forth until it is fully seated on the pipe mount 3 Install the davit and retaining pin Block is oriented downwar...

Page 35: ...ntrol Module The control module has two standard 1 5 8 inch strut channels located on the back These will accept standard pipe mounts not included The control module is mounted within 8 feet of the wi...

Page 36: ...bstacle the idea is to allow the probe to be pulled cleanly off the spool once line runs out rather than allow the winch to be damaged by a permanently tethered probe Mission critical cruises would ty...

Page 37: ...9002203 that is securing the line to the spool The spools are shipped with the line secured to the spool Removal of the middle cover may be necessary Line routing procedure 1 Thru LevelWind rollers 2...

Page 38: ...ass end of winch line thru shackle on tailspool 3 Slide tailspool thru eye of winch line 4 Pull winch line tight at shackle as shown Make sure the eye of the line is not twisted and the eye lines are...

Page 39: ...instructions The entire line section should be replaced after 1000 casts as a preventative measure Installing the Probe Software Follow the instructions shipped with the probe to install the probe sof...

Page 40: ...arts If you are missing parts contact Oceanscience support or call 1 858 842 2600 Check that the system is installed Reference figures Figure 12 through Figure 27 Check that the cables are connected R...

Page 41: ...over Page Page 35 Initial Setup I N S T A L L A T I O N I N C L U D E S T H E F O L L O W I N G S T E P S Connecting the Winch to a PC Verifying Basic Motion Functionality Setting the Home Position De...

Page 42: ...nch to the PC and verify communication 1 Apply power to the Control Module follow Power Up Sequence 2 Start the RapidCAST Interface software The Select Communication Ports dialog will open To re open...

Page 43: ...pool should match See Adjusting the LevelWind Position if an adjustment is needed 6 While paying OUT cable press the Emergency Stop button on the Control Module Verify that the break is engaged on the...

Page 44: ...e contour of the groove and drags the follower along with it When the end of travel is reached the diamond screw thread loops back on itself which causes the pawl to reverse direction and travel the o...

Page 45: ...g internal winch compo nents and cause fouling When feeding line to someone holding the probe on deck it is important to remember that line is flexible The winch is incapable of pushing line out so li...

Page 46: ...d buttons on the Jog and Teach tab 3 Move the probe to the topmost position next to the swivel block at the end of the davit 4 Click the Jog and Teach tab on the rapidCAST Interface software 5 Click t...

Page 47: ...s is the position the winch will go to if the user wishes to bring the probe back on board and is ready to swing the davit around to the deck To define the Dock Position 1 Move the probe to the topmos...

Page 48: ...be is out of the water 3 Click the Jog and Teach tab on the rapidCAST Interface software 4 Click Comm and then click the Teach Button On the Record Position dialog click OK Figure 33 Comm Position The...

Page 49: ...ward 2 Move the probe to just outside the wake 3 Click the Jog and Teach tab on the rapidCAST Interface software 4 Click Launch and then click the Teach Button On the Record Position dialog click OK F...

Page 50: ...s the Recovery position the reel in speed will slow down when near the boat for safety and peace of mind To define the Recovery Position 1 Begin moving the boat forward 2 Move the probe to beyond the...

Page 51: ...and Recovery posi tions and Configuration Settings to a Workspace file rcstprj file The settings will be lost in the event of a power cycle and can be recovered if they are saved To save a Workspace f...

Page 52: ...bject to Restrictions Contained on the Cover Page Quick Review Check that the communication ports are assigned Reference page 36 Check the Basic Motion Functionality Reference page 37 Check that the H...

Page 53: ...sed for deployments 100m To switch between pre defined dive tables 1 Start the rapidCAST Interface software 2 Click the Dive Table tab 3 The CURRENT DEPTH TO TIME COEFFICIENTS IN USE table shows the c...

Page 54: ...rd party software can be used to create virtual serial ports This feature has been successfully tested with EIVA NaviScan survey software working in conjunction with virtual serial ports provided by E...

Page 55: ...adings is chosen as the target The user can customize the size of the candidate pool If the user does not wish to select shallower alternatives this value can be set to 1 causing the candi date pool t...

Page 56: ...being received and can be used to update the Nomi nal Target Depth if the user chooses to enable Auto Depth Paused for Deployment During probe freefall this indicates that Nominal Target Depth is inte...

Page 57: ...be the actual goal Adjusted Target Depth The corrected depth that is passed to the dive table in order to achieve the Nominal Target Depth This is the tweaked depth that is feed the dive table in orde...

Page 58: ...on the Cover Page Performing Your First Cast C A S T I N G I N C L U D E S T H E F O L L O W I N G S T E P S Step 1 Setup Step 2 Set Target Depth Step 3 Set Parameters Step 4 Launch Step 5 Tension Con...

Page 59: ...at may damage the line 2 Attach the desired tailspool to the line see Installing and Connecting the Probe 3 Slowly lower the probe into the water by holding the line and slipping it out by hand 4 Chec...

Page 60: ...the following actions in order The actions have a default setting and are all user settable Review the settings by scrolling through Hold Position time before next task begins with an audio visional n...

Page 61: ...Step 4 Move to Point Launch Move the boat forward at the desired survey speed Click the Start button Watch the video showing a rapidCAST deployment When Auto Repeat is checked once the start button is...

Page 62: ...s Guide Page 56 EAR Controlled Technology Subject to Restrictions Contained on the Cover Page Step 5 Tension Controlled Payout Observe the progress bar as each step is completed Observe the winch ten...

Page 63: ...on the Cover Page Page 57 Step 6 Move to Point Recovery Observe probe as it is rapidly retrieved to the Recovery position Set the Hold position before Recovery equal to the Tension Controlled payout d...

Page 64: ...nection will begin Observe the progress bar as each step is completed Observe the winch tension control arm and line Observe the data download and depth the probe obtained If this depth is slightly di...

Page 65: ...p Check that target depth is set Step 2 Set Target Depth Review Set Parameters and verify hold positions have been entered as needed Step 3 Set Parameters Check that rapidCAST moves through deployment...

Page 66: ...he probe from the line and stow it in its case 3 Secure the line to the spool using a piece of tape 4 Remove the davit and stow it in its case 5 Carefully lift the winch from the pipe mount The cables...

Page 67: ...Settings should not be changed except under verify specific circumstances as outlined in the Resolving Fault Conditions section To change a Winch Configuration Settings 1 Start the rapidCAST Interfac...

Page 68: ...satisfied Verify that the control module is receiving sufficient AC power See Electrical Requirements sec tion Verify that Main Power and Motor Driver Switches are in the On position upper halves are...

Page 69: ...ting from high current potentially leading to loss of the probe and damage to the winch Recover the probe and bring it on board Once the probe is safely stowed turn the Main Power Switch OFF Cutting p...

Page 70: ...e brake state to test its functionality On the Control Module set the Toggle Switch to Local Control Set the Brake Switch to Release and back to Brake repeating this as many times as desired You shoul...

Page 71: ...ose pliers 1 5mm hex key 1 9 64in hex key 1 Stop the vessel to reduce the drag exerted by the probe 2 Remove the winch covers specifically the center cover which hides the spool as well as the motor s...

Page 72: ...ut put torque and reduced output speed The rotational speed of the spool will be less than the input rotational speed of the drill a In general the drill chuck can be coupled directly to the shaft in...

Page 73: ...over Page Page 67 10 Once the probe has been safely recovered the malfunctioning brake must be replaced before fu ture deployments can proceed 11 To install the NEW brake reverse the above procedure s...

Page 74: ...r fas tener to fix the end of the line to the spool so that the line cannot snag any objects The goal is to allow the spool to rotate freely 2 Confirm that the spool encoder is indeed malfunctioning O...

Page 75: ...software and its true position The fastest way to verify the Tension Arm s calibration is to remove all line tension from the arm such that the arm is resting freely against its lower hard stop When t...

Page 76: ...ed with the captured positions click the Apply button to commit these settings to the Control Module If you are unsatisfied you may repeat the capture process as many times as desired or you may cance...

Page 77: ...Ver sion WinchCalibration txt When the Control Module boots up it checks the microSD card for the calibration settings If the calibra tion settings cannot be found or if the card is inaccessible the...

Page 78: ...gy Subject to Restrictions Contained on the Cover Page Using the GUI Windows and Controls The rapidCAST system keeps track of system performance in the Telemetry and Message Log windows To view the sc...

Page 79: ...rapidCAST User s Guide March 2018 EAR Controlled Technology Subject to Restrictions Contained on the Cover Page Page 73 About menu...

Page 80: ...oftware 2 Click the Maintenance tab 3 Click the Software Update button 4 Click the File Location button and navigate to the folder that contains the Config hex and Firm ware hex files Updates may be s...

Page 81: ...0589 LevelWind Roller Vertical rapidCAST 2 8000595 LevelWind Roller Horizontal rapidCAST 2 81J 6000 00 SHACKLE TAILSPOOL UCTD 1 9000994 LINE WINCH RCAST UCTD 500LB WHITE 1500 00 yards 9000996 LINE WIN...

Page 82: ...efore it goes overboard The shackle should be shiny and have no burrs If the shackle has any burrs or damage replace it IMMEDIATELY Figure 40 Bad shackle Arrows show damage from removal with hard tool...

Page 83: ...7 The inline splice should be intact and not walking out There is a high risk of losing the probe if the splice starts to walk out The inline splice is only held by friction and is strongest when load...

Page 84: ...eposits If corrosion caused part of the probe to be visi bly damaged do not redeploy your system Send it back to Oceanscience for inspection 4 Push in the new shackle 5 Brush the screw with marine env...

Page 85: ...ce During intensive surveys the probe loop splice should be replaced daily by cutting 50cm of line from the end and re splicing the termination This will take just a few minutes The entire line sectio...

Page 86: ...hollow core braid splice instructions as shown below Figure 48 Inline Splice Graphic courtesy of Innovative Textiles Inc Replacing the Spool This procedure shows how to replace a spool in the rapidCA...

Page 87: ...ool is supported but does not extract with the following step It is heavy and can cause damage if dropped 9 Carefully slide the encoder assembly to the right away from the chassis Do not remove the sp...

Page 88: ...emoved earlier to finger tight but not torqued 6 Slide the belt onto the front gear Ensure that it rides on the back gear centered The front gear may be offset up to 50 width of the belt and still mai...

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