458499_em124_maintenance_manual.pdf

458499/A March 2020 © Kongsberg Maritime AS

Kongsberg EM 124 Multibeam Echo Sounder

Maintenance Manual

Image: Bathymetry of the Northern Portion of the Mariana Trench.

Courtesy of Dr James V. Gardener, University of New Hampshire.

Kongsberg Maritime AS www.kongsberg.com

Document information

• Product: Kongsberg EM 124

• Document: Maintenance Manual

• Document part number: 458499

• Revision: A

• Date of issue: 17 March 2020

Copyright

The information contained in this document remains the sole property of Kongsberg Maritime AS. No part of this document may be copied or reproduced in any form or by any means, and the information contained within it is not to be communicated to a third party, without the prior written consent of Kongsberg Maritime AS.

Warning

The equipment to which this manual applies must only be used for the purpose for which it was designed. Improper use or maintenance may cause damage to the equipment and/or injury to personnel. You must be familiar with the contents of the appropriate manuals before attempting to operate or work on the equipment.

Kongsberg Maritime disclaims any responsibility for damage or injury caused by improper installation, use or maintenance of the equipment.

Disclaimer

Kongsberg Maritime AS endeavours to ensure that all information in this document is correct and fairly stated, but does not accept liability for any errors or omissions.

Support information

If you require maintenance or repair, contact Kongsberg Maritime’s support organisation. You can also contact us using the following address:

km.hydrographic.support@kongsberg.com. If you need information about our other products, visit https://www.kongsberg.com/maritime.

mailto:km.hydrographic.support@kongsberg.com https://www.kongsberg.com/maritime

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Table of contents

ABOUT THIS MANUAL

KONGSBERG EM 124

System description Technical details System diagram System units

Transducer description Transmitter Unit description Receiver Unit description Processing Unit description Hydrographic Work Station description

Support information

TROUBLESHOOTING

Tools for troubleshooting BIST (Built-In Self Test) dialog box BIST (Built-In Self Test) theory

BIST Introduction CPU Test CBMF test RX unit test TX unit test CBMF-CPU link RX-CBMF link RX channels TX channels RX noise level RX noise spectrum Software date and versions System information

PREVENTIVE MAINTENANCE

Inspecting and cleaning the transducer face Painting the transducer face Inspecting and replacing sacrificial anodes Approved anti-fouling paints

PARTS REPLACEMENT

Tools and equipment required for parts replacement Processing Unit - Parts replacement

Maintenance Manual

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Processing Unit replacement CPU board replacement VadaTech CP219 Ethernet switch replacement - Processing Unit CBMF board replacement Fan unit replacement - Processing Unit Processing Unit fuse replacement

Transmitter Unit - Parts replacement Fan unit replacement - Transmitter Unit 12V Power supply replacement - Transmitter Unit HV Power supply replacement - Transmitter Unit

Receiver Unit - Parts replacement Receiver Unit replacement Power supply replacement - Receiver Unit

SPARE PARTS AND CONSUMABLES

Ordering spare parts Processing Unit - List of spare parts

Processing Unit spare part 436571 CBMF board spare part 430675 CPU board spare part 457015 Power supply spare part 373897 Fan unit spare part 385387

Transmitter Unit - List of spare parts LPTX36 Transmitter board spare part 446679 TX RIO board spare part 426321 Ethernet switch spare part 338124 TXU Fan unit spare part 430443 TXU 12V Power supply spare part 437247 TXU HV Power supply spare part 437225

Receiver Unit - List of spare parts Receiver Unit 1 degree - spare part 424633 Receiver Unit 2 degrees - spare part 424634 Receiver Unit 4 degrees - spare part 424635 RXU Power supply spare part 428206

PROCESSING UNIT

Processing Unit description Processing Unit familiarization Processing Unit front panel description Processing Unit rear panel description Processing Unit circuit boards and modules CPU board

Kongsberg EM 124

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Concurrent PP B12 CPU board overview Concurrent PP B12 CPU board connectors Concurrent PP833 CPU board overview Concurrent PP833 CPU board connectors

CP219 Ethernet switch Ethernet switch overview Ethernet switch connectors

CBMF board CBMF board overview CBMF board configuration CBMF board connectors

TRANSMITTER UNIT

Transmitter Unit familiarization Transmitter Unit bottom panel description Transmitter Unit top panel description Transmitter Unit power supplies RIO-P board - dip switch setting

RECEIVER UNIT

Receiver Unit familiarization Receiver Unit bottom panel description Receiver Unit - dip switch setting

HYDROGRAPHIC WORK STATION

Hydrographic Work Station description Hydrographic Work Station front panel description Hydrographic Work Station rear panel description

DRAWING FILE

213673 TX module outline dimensions 213217 RX module outline dimensions 372053 TX mounting frame - 0.5 degrees 213433 TX mounting frame - 1 degree 213370A TX mounting frame - 2 degrees 213370B TX mounting frame - 2 degrees 213744 RX mounting frame - 1 degree 213389 RX mounting frame - 2 degrees 213803 RX mounting frame - 4 degrees 372981 TX Casing with frame - 0.5 degrees 213754 TX Casing with frame - 1 degree 213755 TX Casing with frame - 2 degrees 213749 RX Casing with frame - 1 degree

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213756 RX Casing with frame - 2 degrees 213810 RX Casing with frame - 4 degrees 365207 Baffle plate 1 dimensions 365208 Baffle plate 2 dimensions 365209 Baffle plate 3 dimensions 426226 Transmitter Unit dimensions 435444 Receiver Unit dimensions 385422 Processing Unit dimensions 378828 HWS dimensions 445723 Rack installation kit dimensions 365290 KM 1000 mounting kit dimensions 409067 Fibre cable kit 370275 Remote Control Unit (K-REM) dimensions 373962 Remote Control Unit (K-REM) wiring diagram

TECHNICAL SPECIFICATIONS

Performance specifications Interface specifications

Datagram formats Interface specifications - Processing Unit - KMall format External sensors requirements Interface specifications - Hydrographic Work Station - KMall format

Weight and outline dimensions Power requirements Environmental requirements Dimensional survey accuracy requirements Alignment specifications

CABLE LAYOUT AND INTERCONNECTIONS

Cable plans

Cable plan, Processing Unit Cable plan - Transmitter Unit Cable plan, Receiver Unit, 1 degree Synchronization overview, 2 Transmitter Units 1 Receiver Unit Remote on/off overview, 2 Transmitter Units 1 Receiver Unit Cable plan, Hydrographic Work Station

List of EM 124 cables Clock synchronization (1PPS) External synchronization Cable drawings and specifications

RS-232 serial line using three wires and RJ45 connector RS-422 serial line using five wires and RJ45 connector

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Clock synchronisation (1PPS) using a coax cable External synchronisation Remote control Remote Control using K-Rem Dummy plug for not using remote control Remote control of Transmitter Unit Remote control of Receiver Unit Remote control overview Transmit Transducer cable Receive Transducer cable

EQUIPMENT HANDLING

Transporting Kongsberg Maritime equipment Lifting units and transportation boxes Inspection of units and transportation boxes after arrival Specifications for storage prior to installation or use Unpacking instructions

Unpacking standard parts and units Unpacking mechanical units Unpacking electronic and electromechanical units Unpacking transducers

Specifications for storage after unpacking

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About this manual

The purpose of this manual is to present the descriptions and drawings required to do basic maintenance tasks on the EM 124 Multibeam Echo Sounder. The equipment described in this manual includes the complete system with associated cabinets, but not those system units provided locally by the customer, installation shipyard or local dealer.

Target audience

The manual is intended for technical personnel; qualified maintenance engineers and technicians. You must understand the general principles of maritime electronic equipment. You must also be familiar with computer hardware, signal processing, interface technology and traditional troubleshooting on electronic and mechanical products.

We assume that you are familiar with the basic acoustic principles of sound in water.

We also expect that you have some experience with multibeam, split-beam and/or single-beam echo sounders in scientific applications.

Online information

All relevant end-user documentation provided for your EM 124 can be downloaded from our website.

• https://www.kongsberg.com/maritime/

Our website also provides information about other Kongsberg products.

Technical information is available for registered users in our password protected database.

Registered trademarks

Observe the registered trademarks that apply.

EM® is a registered trademark of Kongsberg Maritime AS in Norway and other countries.

Windows® is a registered trademark of Microsoft Corporation in the United States and other countries.

About this manual https://www.kongsberg.com/maritime/

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Topics System description, page 11

Technical details, page 12

System diagram, page 13

System units, page 14

Support information, page 17

Kongsberg EM 124 Maintenance Manual

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System description EM 124 multibeam echo sounder is a high performance echo sounder for deep water mapping.

The EM 124 is designed to perform seabed mapping to full ocean depth with an unsurpassed resolution, coverage and accuracy. The system is cost effective, reliable, and easily operated. The design of the EM 124 is based on more than 50 years of hydrographic experience with echo sounders, sonars and underwater positioning for civilian and military use. It is the latest model in a series of deep sea multibeam echo sounders that started with the EM 12 in 1990.

The EM 124 consist of new state-of-the-art electronics and separate transmit and receive transducers in a Mills Cross configuration. It uses the same field-proven transducers as the EM 122, making it easy to upgrade. Care has been taken to design a highly, modular and flexible solution with compact electronics for easier and faster installation. Due to a flexible transducer design, the system can be tailored to almost any required size. The largest standard size, 0.5 x 1 degrees, gives the ultimate system performance in terms of resolution and range, while a smaller 4 x 4 degrees solution allowing full ocean depth surveys even on smaller vessels.

The EM 124 multibeam echo sounder consists of the following main units.

• Transducer arrays

• Transmitter Unit(s)

• Receiver Unit(s)

• Processing Unit

• Hydrographic Work Station

To form a complete system it is also required to have sensors providing vessel attitude, velocity, position, sound speed profile of the water column and speed of sound at the transducer depth.

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Technical details The EM 124 operates at sonar frequencies in the 10.5-13.5 kHz range. The transmit fan is divided into 4 sectors in shallow modes (8 sectors in deep modes) to maximize range capability but also to suppress interference from multiples of strong bottom echoes.

The sectors are transmitted sequentially within each ping, and uses distinct frequencies or waveforms.

The nominal sonar frequency is 12 kHz with an angular coverage sector of up to 150 degrees and 1600 beams per ping. Achievable swath width on a flat bottom will normally be up to 6 times (143 degrees) the water depth. The angular coverage sector is operator controllable or may be set to a fixed range. It may also be set to vary automatically with depth according to achievable coverage. This maximizes the number of usable beams.

The beam spacing is normally high density equidistant with equiangle available.

The transmit fan is split in several individual sectors with independent active steering according to vessel roll, pitch and yaw. This place all beams on a “best fit” to a line perpendicular to the survey line, thus ensuring a uniform sampling of the bottom and 100% coverage.

In dual swath mode the transmit fan is duplicated and transmitted with a small difference in alongtrack tilt. The applied tilt takes into account depth, coverage and vessel speed to give a constant beam separation alongtrack.

The sectors are frequency coded or have FM chirps, and they are transmitted sequentially at each ping. The sector steering is fully taken into account when the position and depth of each beam is calculated, as is the refraction due to the sound speed profile, vessel attitude and installation angles. The pulse length and range sampling rate are variable with depth (auto or manual) for best resolution.

In shallow waters due care is taken to the near field effects through nearfield focusing individually applied in the different sectors.

EM 124 applies one focus range for each of the transmit sectors which are used for shallow water environment. Dynamic beam focusing is used for the reception beams.

The ping rate is mainly limited by the round trip travel time in the water up to a ping rate of more than 5 Hz.

The number of individual TX and RX modules in the two arrays depends on the chosen configuration. The standard types identified by "transmission x reception" beamwidth are:

• 0.5 x 1 degree system: 96 transmit transducer modules and 16 receive transducer modules

• 1 x 1 degree system: 48 transmit transducer modules and 16 receive transducer modules

• 1 x 2 degrees system: 48 transmit transducer modules and 8 receive transducer modules

• 2 x 2 degrees system: 24 transmit transducer modules and 8 receive transducer modules

• 2 x 4 degrees system: 24 transmit transducer modules and 4 receive transducer modules

• 4 x 4 degrees system: 12 transmit transducer modules and 4 receive transducer modules

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System diagram The system diagram identifies the main components of a basic EM 124 system. Only the main connections between the units are shown. Detailed interface capabilities and power cables are not shown.

A Hydrographic Work

Station B Interfaces:

• Sound speed sensors

• Tide

• Centre depth output

C Processing Unit D Interfaces:

• Positioning systems

• Attitude (roll, pitch and heave)

• Sound speed sensor

• Velocity

• Clock

• Trigger input/output

• Clock synchronisation (1PPS) E Transmitter Unit (TXU) F Receiver Unit (RXU) G Transmit transducer modules H Receive transducer modules

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System units

Topics Transducer description, page 14

Transmitter Unit description, page 15

Receiver Unit description, page 15

Processing Unit description, page 15

Hydrographic Work Station description, page 16

Transducer description A transducer is a device that converts one form of energy to another. In an echo sounder system the transducer converts between electric energy and sound.

Receive transducer module

The EM 124 uses separate transducer arrays for transmitting and receiving sound pulses. Both transducer arrays have several modules which are assembled in mounting frames.

The two transducer arrays are normally mounted as “T” or “L” configurations under the vessel’s hull (Mills Cross configuration). The transmit transducer array should be aligned parallel to the vessel’s keel. The receiver transducer array should be aligned 90 ° on the keel. Both transducer arrays should be horizontal on a plane on the keel.

The transmit transducer array contains up to 96 modules in accordance with the chosen beamwidth. Each module contains 18 elements arranged in rows of 6 elements. Each element is individually connected to its corresponding transmitter in the Transmitter Unit(s). It can thus be driven with an unique amplitude level and phase to allow forming of the required transmit sectors with individual steering.

The receive transducer contains up to 16 modules in accordance with the chosen beamwidth. Each module contains 8 transducer staves, and these have individual electrical connections to their corresponding preamplifiers in the Receiver Unit(s). Each stave can thus be given unique amplitude and phase control to allow forming of the required receive beams.

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Transmitter Unit description The EM 124 Transmitter Unit has all transmit electronics, like control processors, power amplifiers, power supply, capacitor battery and Ethernet interface.

The Transmitter Unit is a wall-mounted steel cabinet with integrated shock and vibration absorbers, designed for bulkhead mounting. One 19 inch sub-rack is contained in the cabinet. The number of circuit boards in the sub-rack will depend on the chosen transducer configuration.

Twisted pair Ethernet is used for data communication with the Processing Unit.

The Transmitter Unit is normally located in a "sonar room" close to the transducer arrays.

Receiver Unit description The EM 124 Receiver Unit has all receive electronics, like control processor, amplifiers, Analog-to-Digital Converters, power supply and Ethernet interface.

The Receiver Unit is a small wall-mounted steel cabinet with integrated shock and vibration absorbers, designed for bulkhead mounting. The number of circuit boards in the Receiver Unit will depend on the chosen transducer configuration. Twisted pair Ethernet is used for data communication with the Processing Unit.

The Receiver Unit is normally located in a "sonar room" close to the transducer arrays.

Processing Unit description The EM 124 Processing Unit is provided to process the signals to and from the Transmitter and Receiver Units.

The EM 124 Processing Unit is an industrial computer using both COTS (commercial off-the-shelf) components and custom made components. The unit is designed and tested for rugged use.

The Processing Unit performs the receiver beamforming, bottom detection, and motion and sound speed corrections. It contains all interfaces for time-critical external sensors such as vessel attitude (roll, pitch, heading and heave), vessel position and external clock. More than one sensor of each type may be connected simultaneously, with one in use and all of them logged.

The Processing Unit controls the Transmitter and Receiver units via Ethernet communication, and is also interfaced to the Operator station via Ethernet.

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The 48 V output from the Processing Unit can be used for remote on/off control of the Transmitter and Receiver Units.

The Processing Unit is normally located in a "sonar room" close to the transducer arrays.

The unit can also be placed in the "survey room" or on the bridge.

Hydrographic Work Station description The Hydrographic Work Station is the operator station for the EM 124.

A dedicated maritime computer is provided with the EM 124 Multibeam Echo Sounder. It is set up with all necessary software.

The Hydrographic Work Station is based on the Microsoft® Windows 10 operating system.

The Hydrographic Work Station is normally mounted near the operator work space.

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Support information Should you need technical support for your EM 124 you must contact a Kongsberg Maritime office. A list of all our offices is provided on our website. You can also contact our main support office in Norway.

A 24 hour telephone support service may also be available depending on your Service Level Agreement.

• Company name: Kongsberg Maritime AS

• Address: Strandpromenaden 50, 3183 Horten, Norway

• Website: https://www.kongsberg.com/maritime/

• E-mail address: km.hydrographic.support@kongsberg.com

Kongsberg EM 124 mailto:km.hydrographic.support@kongsberg.com

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Troubleshooting

Topics Tools for troubleshooting, page 19

BIST (Built-In Self Test) dialog box, page 20

BIST (Built-In Self Test) theory, page 23

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Tools for troubleshooting Efficient EM 124 troubleshooting requires a good knowledge of its functionality and design. Specific tools may also be required for certain tasks.

The following tools are relevant for troubleshooting the Kongsberg EM 124 Multibeam Echo Sounder.

• Built-In Self Test (BIST)

• Analysis of the data presentations made by the EM 124

• Messages

• Visual checks

• Relevant measurements with applicable test instruments

• Test and verification procedures

• Your own knowledge of how the system works

We assume that you are equipped with a standard set of tools. This tool set must comprise the normal tools for electronic and electromechanical tasks. This includes different screwdriver types, pliers, spanners, a cable stripper, a soldering iron, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

Note

If one or more special tools are required for a task, these are specified in the relevant procedure.

It is impossible to create a detailed list of all possible errors and error symptoms in the

EM 124.

However, key components that fail will in most cases be detected by the tools you have available.

The most important tool is your own knowledge about the EM 124. Based on a list of the main components in the system, brief descriptions of what they do and how they work, including suggested certain symptoms, you may work out the possible solutions.

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BIST (Built-In Self Test) dialog box The BIST dialog box provides several automatic tests to check the operation of the echo sounder system.

How to open

• SIS: Select Installation Parameters on the View menu. Select the Installation

Parameters icon and select BIST.

• K-Controller: Select the Installation Parameters icon and select BIST.

Description

The BIST (Built-In Self Test) options provide a number of automatic tests that may be started to check the operation of the echo sounder system.

Various test are available, depending on what system you have.

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Details

CPU Test

This test presents the CPU type, the CPU clock frequency, the current and maximum temperatures for the CPU die and for the CPU board. In addition some key voltages are reported, and finally the network addresses for the board’s interfaces.

CBMF test

This test presents the CBMF board temperature, the internal power supply voltages.

In addition software and firmware versions are displayed.

RX unit test

This test presents the internal temperatures and voltages in the receiver electronics.

In addition software and firmware versions are displayed.

TX unit test

This test presents the internal temperatures and voltages in the transmitter electronics. In addition software and firmware versions are displayed.

CBMF-CPU link

This test checks CBMF board(s), Ethernet connection and the parallel bus interface between the CBMF board(s) and the CPU circuit board. A large set of known data is transferred from the CPU unit on Ethernet via CBMF back to the CPU board.

The data received is checked by the CPU board.

RX-CBMF link

This test checks the GBit interface between the RX unit and the CBMF boards. A large set of known data is transferred from RX unit via CBMF to the CPU board on parallel bus. The data received is checked by the CPU board.

RX-CPU link

This test is not implemented yet.

RX channels

The Receiver Unit has a programmable signal generator board that is used to inject a test signal at the preamplifier inputs in the Receiver Unit. The BIST report displays the measured RX transducer impedance for all RX channels. This test may fail at very high noise levels.

TX channels

This test checks the impedance of all TX elements. This is done by measuring the voltage and current used by all individual transmitters. This test may fail at very high noise levels.

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RX noise level

This test measures the average isotropic spectral noise level for each receiver channel (in dB rel 1 μPa/Hz) for different frequency bands. The receiver directivity index, the transducer sensitivity and the filter bandwidth is used to convert to isotropic spectral noise level. On a quiet ship away from noise sources, the noise level should normally be below 45 dB.

RX noise spectrum

This test measures the isotropic spectral noise level for each receiver channel as done in the RX noise level test. The noise spectrum level is displayed for small frequency bands for groups of 32 channels. In addition the average level for all channels are displayed. This spectrum test can be used to search for external noise sources.

Software date and versions

This test presents the software date and versions for the system components.

System information

This test acquires information needed (serial numbers, software versions, BIST results etc.) for a status report.

Save tests and open folder

Select Save tests and open folder to save the test results as a text file.

Clear

Select Clear to delete the tests already run.

PU System test result

All the tests will be listed as they are done.

Time

The time the test was run showing as yyyymmdd-hhmmss.

Result

The result showing as Passed or Failed.

Description

A short description of the test. Select the description or the text file to get more details.

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BIST (Built-In Self Test) theory

Topics BIST Introduction, page 24

CPU Test, page 25

CBMF test, page 26

RX unit test, page 27

TX unit test, page 28

CBMF-CPU link, page 29

RX-CBMF link, page 30

RX channels, page 31

TX channels, page 32

RX noise level, page 33

RX noise spectrum, page 34

Software date and versions, page 35

System information, page 35

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BIST Introduction The purpose of the offline BIST system is to detect errors and locate the failed module.

The BIST tests are organized in a sequence, and tests module by module. The CPU executes the BISTs and sends the BIST reply to the operator station.

Temperature, voltage, communication and firmware versions of each board and module are tested.

A Processing Unit B Transmitter Unit (TXU) C Receiver Unit D Transmit transducer array E Receive transducer array

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CPU Test Checks the CPU board in the in the EM 124 Processing Unit.

This test presents the CPU type, the CPU clock frequency, the current and maximum temperatures for the CPU die and for the CPU board. Checks all beamformer and signal processing boards (CBMF) in the EM 124 Processing Unit.

In addition some key voltages are reported, and finally the network addresses for the board’s interfaces.

Dark green modules are to be tested. Light green modules have to function to be able to perform current test.

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CBMF test Checks all beamformer and signal processing boards (CBMF) in the EM 124 Processing Unit.

This test presents the CBMF board temperature, the internal power supply voltages. In addition software and firmware versions are displayed.

Dark green modules are to be tested. Light green modules have to function to be able

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RX unit test Checks the receiver electronics in the EM 124 Receiver Unit.

This test presents the internal temperatures and voltages in the receiver electronics. In addition software and firmware versions are displayed.

Dark green modules are to be tested. Light green modules have to function to be able

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TX unit test Checks the transmitter electronics in the EM 124 Transmitter Unit.

This test presents the internal temperatures and voltages in the transmitter electronics. In addition software and firmware versions are displayed.

Dark green modules are to be tested. Light green modules have to function to be able

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CBMF-CPU link Checks the parallel bus interface between the CBMF board and the CPU board.

This test checks CBMF board(s), Ethernet connection and the parallel bus interface between the CBMF board(s) and the CPU circuit board. A large set of known data is transferred from the CPU unit on Ethernet via CBMF back to the CPU board. The data received is checked by the CPU board.

Dark green modules are to be tested. Light green modules have to function to be able

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RX-CBMF link This test checks the GBit interface between the RX unit and the CBMF boards.

A large set of known data is transferred from RX unit via CBMF to the CPU board on parallel bus. The data received is checked by the CPU board.

Dark green modules are to be tested. Light green modules have to function to be able

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RX channels Checks the RX channels including transducers by injecting a test signal at receiver input.

The Receiver Unit has a programmable signal generator board that is used to inject a test signal at the preamplifier inputs in the Receiver Unit. The BIST report displays the measured RX transducer impedance for all RX channels.

Dark green modules are to be tested. Light green modules have to function to be able

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TX channels Checks all TX channels including the transducers.

This test checks the impedance of all TX elements. This is done by measuring the voltage and current used by all individual transmitters.

Dark green modules are to be tested. Light green modules have to function to be able

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RX noise level Checks the isotropic spectral noise level.

This test measures the average isotropic spectral noise level for each receiver channel (in dB rel 1 μPa/Hz) for different frequency bands. The receiver directivity index, the transducer sensitivity and the filter bandwidth is used to convert to isotropic spectral noise level.

Dark green modules are to be tested. Light green modules have to function to be able

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RX noise spectrum Checks the isotropic spectral noise level.

This test measures the isotropic spectral noise level for each receiver channel as done in the RX noise level test. The noise spectrum level is displayed for small frequency bands for groups of 32 channels. In addition the average level for all channels are displayed.

This spectrum test can be used to search for external noise sources.

Dark green modules are to be tested. Light green modules have to function to be able

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Software date and versions Checks the software date and versions.

This test presents the software date and versions for the system components.

Dark green modules are to be tested. Light green modules have to function to be able to perform current test.

System information Generates a status report for the EM 124 system.

This test acquires information needed (serial numbers, software versions, BIST results etc.) for a status report. This report can be sent to the factory to update the EM 124 product database.

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Preventive maintenance

Topics Inspecting and cleaning the transducer face, page 37

Painting the transducer face, page 39

Inspecting and replacing sacrificial anodes, page 41

Approved anti-fouling paints, page 42

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Inspecting and cleaning the transducer face Marine growth (biological fouling) on the transducer face reduces the EM 124 performance. For this reason, it is important to keep the transducer face clean. Every time your vessel is in dry dock, you must remove the marine growth. At the same time, you must inspect the transducer closely for physical damage.

Prerequisites

The following tools and consumables are required.

• Personal protection

• Fresh water

• A mild synthetic detergent and a plastic brush

• A piece of wood or plastic without sharp corners

• Citric acid (<50%) (only if required)

Context

During normal use, the transducer is subjected to biological fouling. If this marine growth is excessive, it will reduce the performance of the EM 124. Whenever opportunity arise, typically when the vessel is dry-docked, the transducer face must be cleaned for shells and other marine growth.

It is important to check the transducer for physical damage. Any cracks, fractures or holes in the red protective coating may result in a water leak, and a leak may cause irreparable damage to the transducer.

A transducer must always be handled as a delicate instrument. Incorrect actions may damage the transducer beyond repair. Observe these transducer handling rules:

• Do not activate the transducer when it is out of the water.

• Do not handle the transducer roughly and avoid impacts.

• Do not expose the transducer to direct sunlight or excessive heat.

• Do not use high-pressure water, sandblasting, metal tools or strong solvents to clean the transducer face.

• Do not damage the outer protective skin of the transducer face.

• Do not lift the transducer by the cables.

• Do not step on the transducer cables.

• Do not damage the transducer cables, and avoid exposure to sharp objects.

Procedure 1 Allow for sufficient access to clean and inspect the entire surface of the transducer.

2 Remove biological fouling carefully using a plastic brush, a suitable synthetic detergent and fresh water.

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Biological material which is strongly rooted in the substrate can be removed carefully with a piece of wood or plastic.

If required, you can also use citric acid. Apply, leave it working for several hours, and rinse thoroughly with fresh water.

Note

Do not use high-pressure water, sandblasting, metal tools or strong solvents to clean the transducer face.

Do not damage the outer protective skin of the transducer face.

3 Allow the transducer surface to dry.

4 Do a thorough visual inspection of the transducer. Check for dents, scratches, holes or other damage to the surface.

If you suspect damage, take a high resolution photo. Contact your dealer or the Kongsberg support organization for advice.

5 Apply anti-fouling paint as described in the dedicated procedure.

Note

Because some paint types may be aggressive to the polyurethane in the transducer, consult our list of approved paints.

The list can also be found on Kongsberg Maritime (https://www.kongs-berg.com/maritime/).

Kongsberg EM 124 Maintenance Manual

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Painting the transducer face Marine growth (biological fouling) on the transducer face reduces the EM 124 performance. We recommend that you paint the transducer face immediately after installation, and then again as often as required to maintain the protection.

Prerequisites

The following tools and consumables are required.

• Personal protection

• Fresh water

• A mild synthetic detergent and a plastic brush

• Fine-grade sandpaper (240 inch grit size)

• Primer

• Anti-fouling paint

• Wet film gauge

• Airless spray

Because some paint types may be aggressive to the polyurethane in the transducer, consult our list of approved paints.

Context

The transducer has not been designed with any protection against biological fouling.

Anti-fouling paint may therefore be applied to the transducer face. To minimize the negative acoustical effects the layer of anti-fouling paint must be as thin as possible.

Note

The anti-fouling paint will reduce the acoustical performance of the transducer. The surface roughness of the transducer substrate and the thickness of the paint may also influence the performance. Kongsberg Maritime cannot be held responsible for any negative consequences of the anti-fouling paint.

Observe the relevant instructions and safety information provided by the paint manufacturer.

Procedure 1 Clean the transducer thoroughly.

Make sure that you remove all oil grease residues, as well as salt and other contamination.

2 Allow the transducer surface to dry.

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3 Abrade the transducer surface using a sanding paper with 240 inch grit size.

Do not exceed a surface roughness (Rmax) of 35 microns as this can influence the EM 124 performance.

4 Remove all dust.

5 Apply the primer, and let it dry.

6 Apply the paint.

Observe the instructions provided by the paint manufacturer. Use airless spray.

Apply the minimum specified film thickness per coat and for the complete layer.

It is not possible to measure dry film thickness on transducer surface. You must therefore use a wet film gauge to frequently measure the paint thickness.

Note

We strongly recommend that you do not use a paintbrush and/or a roller.

7 Allow the paint to dry.

Further requirements

The contractor or shipyard must keep a daily paint log recording all relevant information from the surface treatment.

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Inspecting and replacing sacrificial anodes Anodes are used on various units to prevent metals from corroding in salt water.

Context

Anodes are constructed of a metal alloy with an active voltage that is greater than the metal of the structure; thus, the anode corrodes before the material it is protecting. The three main alloys used are magnesium, aluminum, and zinc.

The sacrificial anodes must be inspected every time the vessel is in dry dock. Replace the anodes if they are damaged or severely corroded.

Procedure 1 Inspect all anodes for damage and corrosion.

2 Loosen the mounting screws and remove the anode.

3 Clean the new anode and mounting surface using Isopropyl alcohol on a soft cloth or paper wipe.

4 Grease the mounting screws and threads with Aqua Shield or Molykote P-40 paste.

5 Mount the new anode using the same screws. Make sure there is good electrical contact with the unit.

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Approved anti-fouling paints This is our list of approved antifouling paints for all transducer types. Always refer to the manufacturer's documentation and data sheets for a complete procedure and for relevant safety information.

Important

Do not paint the transducer with traditional hull plating paint. Use only the correct type of approved paint specified.

Do not use high-pressure water, sandblasting, metal tools or strong solvents to clean the transducer face.

Jotun

• Manufacturer: Jotun

• Address: P.O.Box 2021, N-3248 Sandefjord, Norway

• Manufacturer’s website: http://www.jotun.com

Products:

• SeaQuantum Ultra S

– Primer: Safeguard Universal ES Apply 80 µm wet film thickness (50 µm dry film thickness).

– Paint: SeaQuantum Ultra S Apply 250 µm wet film thickness (125 µm dry film thickness).

• Seaforce 200 AV

– Primer: Safeguard Universal ES AV

Apply 70 µm wet film thickness (50 µm dry film thickness).

– Paint: Seaforce 200 AV

Apply 140 µm wet film thickness (90 µm dry film thickness).

Data sheets and application guides can be downloaded from:

http://www.jotun.com/ww/en/b2b/technical-info/tds/index.aspx

International Marine Coatings

• Manufacturer: International Marine Coatings

• Address: Stoneygate Lane, Felling, Gateshead, Tyne & Wear, NE10 0JY United

Kingdom

• Manufacturer’s website: www.international-marine.com

Products:

• Intersleek 1100SR

Kongsberg EM 124 Maintenance Manual http://www.jotun.com http://www.jotun.com/ww/en/b2b/technical-info/tds/index.aspx http://www.international-marine.com/

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– Primer: Intersleek 737 Apply 50 µm dry film thickness.

– Paint: Intersleek 1100SR Apply 150 µm dry film thickness.

• Intersmooth 7465Si SPC

– Primer: Intergard 269

Apply 40 µm dry film thickness.

– Paint: Intersmooth 7465Si SPC

Apply 100 µm dry film thickness.

The list can also be found on Kongsberg Maritime (https://www.kongsberg.com/mar-itime/).

Preventive maintenance

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Parts replacement

Topics Tools and equipment required for parts replacement, page 45

Processing Unit - Parts replacement, page 47

Transmitter Unit - Parts replacement, page 66

Receiver Unit - Parts replacement, page 83

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Tools and equipment required for parts replacement In order to safely remove and replace printed circuit boards modules, generic and specific tools are required.

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electronic and electromechanical tasks. This includes different screwdriver types, pliers, spanners, a cable stripper, a soldering iron, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

• Screwdriver (various types and sizes)

• Allen keys (various sizes)

• Cable cutter, knife and/or scissors

• Wire stripper

• Pliers (various types and sizes)

• Spanner (various sizes) (US: Wrench)

• Tweezers

Note

If you need specific consumables, or if special tools and/or test instruments are required, these are identified in the relevant procedure(s).

Note

Circuit boards and electronic modules are delicate items. They may work year after year in an advanced product, but then fail due to a small spark of static electricity. For this reason, it is very important that they are properly handled and protected during handling. You must be familiar with the applicable handling precautions. Take all necessary steps to avoid Electrostatic Discharge (ESD).

As a minimum, the following precautions must be taken:

1 For correct and safe handling of printed circuit boards and electronic modules, you need a suitable working area. The working area must be covered by an approved conductive service mat that has a resistance of between 50 kΩ and 2 MΩ, and is connected directly to a reliable earth point via its earthing cord.

2 You - and all other service personnel involved - must wear a wristband in direct contact with the skin. The wristband must be electrically connected to the service mat.

3 Printed circuit boards and electronic modules must be placed on the conductive service mat during installation and maintenance operations.

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4 If, for any reason, it is necessary to move the circuit board from the conductive service mat, it must be placed in an approved antistatic transportation container (for example a static shielding bag) before transportation.

5 During installation and servicing, all electrical equipment (for example soldering irons and test equipment) must be earthed.

WARNING

Personell must check that all the equipment is earthed before power is connected or switched on.

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Processing Unit - Parts replacement

Topics Processing Unit replacement, page 48

CPU board replacement, page 51

VadaTech CP219 Ethernet switch replacement - Processing Unit, page 54

CBMF board replacement, page 57

Fan unit replacement - Processing Unit, page 60

Processing Unit fuse replacement, page 63

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Processing Unit replacement If a Processing Unit fails to operate, it must be replaced with a new unit. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

The Processing Unit is the central controlling device in the EM multibeam system. It is provided to process the signals to and from the transducer(s).

Note

These procedures will instruct you to handle electronic circuit boards and/or modules.

Before doing so, make sure that you are familiar with the applicable handling precautions. Follow the relevant handling procedures for circuit boards and electronic modules.

Topics Removing the Processing Unit, page 49

Installing the Processing Unit, page 50

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Removing the Processing Unit

One or two Processing Units are used in the EM 124 system. The complete Processing Unit can be supplied as a spare part.

Prerequisites

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for mechanical tasks. This includes different screwdriver types, pliers, adjustable spanners, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

Context

Refer to the detailed information in the Cable layout and interconnections chapter.

Procedure 1 Locate the unit you wish to remove.

The Processing Unit is normally mounted in a cabinet, in a rack or placed on a table.

2 Turn off the EM 124.

3 Disconnect the power cable on the rear side of the unit.

4 Disconnect the cables.

5 Loosen the unit by removing the mounting bolts on both sides.

6 Grab a firm hold of the unit, and pull it straight out.

7 Place the unit on a conductive service mat on your work table.

Further requirements

To return the unit for repair or replacement, follow the relevant handling instructions.

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Installing the Processing Unit

The Processing Unit is designed to be installed in a 19" rack.

Prerequisites

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electronic and electromechanical tasks. This includes different screwdriver types, pliers, spanners, a cable stripper, a soldering iron, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

Context

Refer to the detailed information in the Cable layout and interconnections chapter.

Procedure 1 Grab a firm hold of the unit, and push it straight in.

2 Fasten the unit by securing the mounting bolts on both sides.

3 Connect the power cable on the rear side of the unit.

4 Connect the cables.

Note

When you connect the cables, make sure that they are all properly secured, and able to withstand the vibration and movements of the vessel.

Further requirements

Once the unit has been installed, follow the normal procedure to turn on the EM 124.

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CPU board replacement If a CPU board fails to operate, it must be replaced with a new circuit board. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

This is a generic photo. The CPU board used by the EM 124 may look slightly different due to minor design changes on the protective lid and/or the front panel.

There is one CPU board in the Processing Unit.

Note

These procedures will instruct you to handle electronic circuit boards and/or modules.

Before doing so, make sure that you are familiar with the applicable handling precautions. Follow the relevant handling procedures for circuit boards and electronic modules.

Topics Removing the CPU board, page 52

Installing the CPU board, page 53

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Removing the CPU board

If a CPU board fails to operate, it must be replaced with a new circuit board. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

Prerequisites

This is a generic photo. The CPU board used by the EM 124 may look slightly different due to minor design changes on the protective lid and/or the front panel.

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electromechanical tasks. This includes different screwdriver types, pliers, adjustable spanners, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

Context Removal is done by pulling the board straight out of the Processing Unit.

Procedure 1 Turn off the Processing Unit.

2 Disconnect the power cable on the rear side of the unit.

3 Identify the circuit board you wish to remove.

4 Disconnect all relevant cables.

5 Loosen the screws. (A) 6 Loosen the circuit board by pushing the two red locking devices on the handles. (B) 7 Push the handles outward. (C) 8 Grab the handles and pull the circuit board straight out.

9 Place the circuit board on a conductive service mat on your workbench.

Further requirements

To return the circuit board for repair or replacement, follow the relevant handling instructions.

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Installing the CPU board

If a CPU board fails to operate, it must be replaced with a new circuit board. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

Prerequisites

This is a generic photo. The CPU board used by the EM 124 may look slightly different due to minor design changes on the protective lid and/or the front panel.

A new circuit board must be available.

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electromechanical tasks. This includes different screwdriver types, pliers, adjustable spanners, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment. Depending on the chosen installation method, additional tools may be required.

Procedure 1 Make sure that all AC mains power has been disconnected.

2 Grab the handles and push the circuit board straight in.

3 Push the handles inward. (C) 4 Tighten the screws. (A) 5 Connect the cables.

6 Connect AC mains power.

Further requirements

Once the circuit board has been installed, follow the normal procedure to turn on the

EM 124.

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VadaTech CP219 Ethernet switch replacement - Processing Unit If a VadaTech CP219 Ethernet switch fails to operate, it must be replaced with a new switch. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

The VadaTech CP219 board is used as an Ethernet switch in the EM 124 Processing Unit.

Note

These procedures will instruct you to handle electronic circuit boards and/or modules. Before doing so, make sure that you are familiar with the applicable handling precautions.

Follow the relevant handling procedures for circuit boards and electronic modules.

Topics Removing the VadaTech CP219 Ethernet switch , page 55

Installing the VadaTech CP219 Ethernet switch, page 56

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Removing the VadaTech CP219 Ethernet switch

If a VadaTech CP219 Ethernet switch fails to operate, it must be replaced with a new switch. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

Prerequisites

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electromechanical tasks. This includes different screwdriver types, pliers, adjustable spanners, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

Context Removal is done by pulling the board straight out of the Processing Unit.

Procedure 1 Turn off the Processing Unit.

2 Disconnect the power cable on the rear side of the unit.

3 Identify the circuit board you wish to remove.

4 Disconnect all relevant cables.

5 Loosen the screws. (A) 6 Loosen the circuit board by pushing the red locking device on the handle. (B) 7 Push the handle to the right. (C) 8 Grab the handle and pull the circuit board straight out.

9 Place the circuit board on a conductive service mat on your workbench.

Further requirements

To return the circuit board for repair or replacement, follow the relevant handling

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Installing the VadaTech CP219 Ethernet switch

If a VadaTech CP219 Ethernet switch fails to operate, it must be replaced with a new switch. All replacement tasks must be done according to the specified procedures, and you must follow the relevant safety instructions.

Prerequisites

A new circuit board must be available.

You must be equipped with a standard set of tools. This tool set must comprise the normal tools for electromechanical tasks. This includes different screwdriver types, pliers, adjustable spanners, etc. Each tool must be provided in various sizes. We recommend that all tools are demagnetized to protect your equipment.

Procedure 1 Make sure that all AC mains power…