Tech Manual RB-573-05 Sect. 1_2.pdf

1-2

GENERAL DESCRIPTION AND SPECIFICATIONS

1. INTRODUCTION

The MARKEY DUTW-9-11 Traction Winch system is designed for deep water science vessels, for trawl, dredge, and ROV handling applications. The system is composed of a traction winch, two stowage winches, an electro-hydraulic power unit, and control stations. One stowage winch is spooled with 45,000 feet of 9/16 inch diameter 3 x 19 construction torque balanced wire rope (MacWhyte) , and the other with 30,000 feet of 0.680 inch diameter coaxial cable (Rochester A301241). Alternately, 30,000 feet of 0.681 diameter power-optic cable (Rochester A302351) may be spooled. The traction winch, stowage winches, the electro-hydraulic power unit, and the local control station are located in the winch compartment.

For the system general arrangement, refer to the Winch Compartment Layout, Drawing D-41083, page 1-1.

The MARKEY DUTW-11 Traction Winch multiplies the low line pull of the stowage winches up to the maximum 30,000 pounds force line pull.

It may be operated with either of the two stowage winches. The traction winch features cantilevered drums, with 6 grooves, which are a one-piece bolt-on rim design for replaceability, and a pressure wheel at the line exit point to prevent slack accumulation between the traction and stowage winches.

For the Traction Winch general arrangement, refer to the Traction Winch Outline Drawing C-3 2 63 0, page-rj--, .:- .

The MARKEY DUSR-11-30 and DUSR-11-48 Stowage Winches spool wire rope or cable at low tension. The stowage winches have removability drums which are fitted with Lebus grooved drum shells, and are servo controlled so that all layers are stowed at the inhaul line tension which has been set. It is adjustable between 800 lbf and 3500 lbf .

Payout line tension is adjustable through the programmable logic controller only.

For the Stowage Winch general arrangements, refer to:

stowage Winch, Type DUSR-11-30 (fo_~ __ 9./16 diameter wire rope), Outline Drawing D-41078, page '7=- '7, :;

Stowage Winch, Type DUSR-11-48 (for 0.680 diameter cable), Outline Drawing D-41113, page ·7....::::?; ---'

The MARKEY 150 HP Electro-Hydraulic Power unit uses a 3-phase electric motor and three variable displacement hydraulic pumps to hydrostatically drive the winches. The 100 gallon reservoir, winch selector valve, winch cross-port relief valves, gauge panel, hydraulic manifolds, motor starter panel, and'system interface box are all integrated into the HPU. The system interface box houses the programmable logic controller. A liP. I. D '~ 11 controller module provides

~ the servo-control for the stowage winches.

System setup parameters are selected at the System Interface Box.

The switches located on the door select the following:

The load pin to be active: The flag block or at the crane base .

1-3 The stowage winch to be active: Port or starboard.

The control station to be active, 4 positions: Local, aft, lab, and "standby/heaters only".

The following selector switches and the stowage line tension potentiometers and their related displays are located inside the systems interface box, behind the lockable door to limit access:

Inhaul Tension Adjustment potentiometer (servo-controlled), with display (lbs).

Mode Selector switch, auto-manual.

Manual Direction Select switch, inhaul-auto-payout.

Manual Speed Control potentiometer.

Horsepower limiter (servo-control), with display (amps).

The controls and displays which are located on the motor starter panel are:

External mains disconnect

Hour meter

Ammeter

Panel reset

HPU start and stop push-buttons

HPU run indicator lamp (green)

Heaters on-off selecto~ switch

Heater on indicator lamp (amber)

High temperature shut down indicator lamp (red)

Low oil shut down indicator lamp (red)

Low oil warning indicator lamp (amber)

For the Hydraulic Power unit general arrangement, refer to Outline Drawing 0-41089, page 8-1.

The controls and display which are furnished with each control station are:

Speed-direction control (joy stick)

HPU start and stop push-buttons

HPU run indicator lamp (green)

Emergency stop r

1-4 station active indicator lamp

Two winch active indicator lamps (amber)

Two load pin active indicator lamps (amber)

Line instrumentation display for scope, speed, and tension.

2. IDENTIFICATION

The components of the system, the traction winch, two stowage winches, the electro-hydraulic power unit, and the control stations, are each fitted with a identification plate. These plates are stamped with the component name, MARKEY type designation, capacity, serial number, and date of manufacture. The serial number is also welded onto each of the traction and stowage winch base frames.

3. APPROXIMATE WEIGHTS

Traction Winch DUTW-11:

Approximate net weight .............................. 11,600 lbs.

Approximate wet weight .............................. 11,700 lbs.

stowage Winch DUSR-11-30:

Approximate net weight .............................. 16,000 lbs.

Approximate wet weight .............................. 16,100 lbs.

Approximate weight with 9/16" 3 x 19 wire (in air) .. 38,300 lbs.

stowage Winch DUSR-11-48:

Approximate net weight .............................. 17,000 lbs.

Approximate wet weight .............................. 17,100 lbs.

Approximate weight with 0.680 coax. cable (in air) .. 38,000 lbs.

150 HP Hydraulic Power Unit:

Approximate net weight ............................... 5,000 lbs.

Approximate wet weight ............................... 5,800 lbs.

4. STOWAGE DRUM SPECIFICATIONS

The following dimensions apply to both the DUSR-11-30 and the DUSR-11-48 Stowage Winches:

Barrel Diameter: 48 inches (diameter under Lebus shell) Barrel Length: 75 inches Flange Diameter: 76 inches

Rated Drum Capacities:

DUSR-11-30: 45,000 feet of 9/16 inch diameter 3 x 19 torque balanced wire rope

DUSR-11-48: 30,000 feet Of 0.680 inch diameter coaxial cable, or alternately, 30,000 feet of 0.681 inch diameter power-optic cable

1-5

5. SYSTEM PERFORMANCE

Rated Line Pull: 30,000 lbs. at 100 ftjmin. to 10,000 lbs . at 330 ftjmin.

Inhaul Spooling Tension: Adjustable 800 to 3500 lbs.

Payout Spooling Tension: Adjustable only by entry of a new value into a programmable logic controller register.

Note that the stowage winch drives are layer compensated. All layers are spooled at the same tension.

See Drum Capacity and Performance Charts, pages 1-6, 1-7 , and 1-8.

MARKEY TRACTION & STORAGE ~INCH DRUM CHART

MMCo Type DUT~-9-11

Cable Dia )g Dia

Barel Dia Flng Dpth Act Layers

USE LAYERS

yer La Num ber

0.580 76.000 48.000 14.000 24.138

76.420 75.260 74.100 72.940 71.780 70.620 69.460 68.300 67.140 65.980 64.820 63.660 62.500 61.340 60.180 59.020 57.860

56.700 55.540 54.380 53.220 52.060 50.900 49.740 48.580

Pitch Diam.

Done For AGOR24

Fce ~idth 75.000 Nom.~raps 127.371 at enter- ~RAPS 127.500 & Air Gap 1.050 Gap % /100 0.014

20.007 2,551 52,155

19.703 2,512 49,605

19.399 2,473 47,092

19.096 2,435 44,619

18.792 2,396 42,184

18.488 2,357 39,788

18.185 2,319 37,431

17.881 2,280 35,113

17.577 2,241 32,833

17.274 2,202 30,592

16.970 2,164 28,389 16_666 2,125 26,226

16.363 2,086 24,101

16.059 2,047 22,014

15.755 2,009 19,967

15.451 1,970 17,958

15.148 1,931 15,988

14.844 1,893 14,057

14.540 1,854 12,164

14.237 1,815 10,310

13.933 1,776 8,495

13.629 1,738 6,719

13.326 1,699 4,981

13.022 1,660 3,282

12.718 1,622 1, 622

Feet/ Feet/ Feet ~rap Layer ON

1.5% recalc.

-4,605 -2,092

2,816 5,212 7,569 9,887

12,167 14,408 16,611 18,774 20,899 22,986 25,033 27,042 29,012 30,943 32,836 34,690 36,505 38,281 40,019 41,718 43,378 45,000

Feet

OFF

Date = NOV 04, 93 Drive = HYD, 150 HP

~t. in H2O 0.428 lb.

Ul t.Stngth 32,500 lb.

Deploy 45,000 feet Tai l Hold 3,500 lbf Line Pull 30,000 lbf Line Speed 100.000 ft/min HPL Ratio 3.300

3,500 100.00 30.5 3,500 100.00 30.5 3 500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100 . 00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100 . 00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5 3,500 100.00 30.5

PULL, Lbs Ft/ Meters/ Tai l Hold Min Min

1-"

** 48 CORE X 75 ~IDE X 76 FLANGE DRUM

** 45,000 FT OF 9/16 3X19 ~IRE ROPE

** 22 LAYERS

(Traction Output) (High Pull) (Traction Output)

330.00 100.6 -1,971 25

330.00 100.6 -896 24 330 . 00 100.6 163 23

330.00 100.6 1,205 22

330.00 100.6 2,231 21

330.00 100.6 3,239 20

330.00 100.6 4,232 19

330.00 100.6 5,208 18

330.00 100.6 6,167 17

330.00 100.6 7,109 16

330.00 100.6 8,035 15

330.00 100.6 8,945 14

330.00 100.6 9,838 13

330.00 100.6 10,714 12

330.00 100.6 11,574 11

330.00 100.6 12,417 10

330.00 100.6 13,244 9

330.00 100.6 14,054 8

330.00 100 . 6 14,847 7

330.00 100.6 15,624 6

330.00 100.6 16,384 5

330.00 100.6 17,128 4

330.00 100.6 17,855 3

330.00 100.6 18,566 2

330.00 100 . 6 19,260 1

Ft/ Meters/ H20 ~t. Layer

Min Min of ~i re Number

<---- ----------------------STORAGE ~INCH---------------------------- - > <--- MAX PULL ---> <-- LIGHT LINE - ->

30,000 Lbs 9,091 Lbs

<------------ TRACT! ON ~I NCH ----------------->

AG0916B.CHT

1-1

MARKEY TRACTION & STORAGE WINCH DRUM CHART

MMCo Type DUTW-9-11 Done For AGOR24

Date = NOV 04, 93 Drive = HYD, 150 HP

** 48 CORE X 75 WIDE X 76 FLANGE DRUM

** 30,000 FT OF .680 EM CABLE

Cable Dia 19 Dia

Isarel Dia Flng Dpth Act Layers

USE LAYERS

Layer Number

0.680 76.000 48.000 14.000 20.588

75.880 74.520 73.160 71.800 70.440 69.080 67.720 66.360 65.000 63.640 62.280 60.920 59.560 58.200 56.840 55.480 54.120 52.760 51.400 50.040 48.680

Pitch Diam.

Fce Width Nom.Wraps enter- WRAPS

19.865 19.509 19.153 18.797 18.441 18.085 17.729 17.373 17.017 16.661 16.305 15.949 15.593 15.237 14.881 14.525 14.169 13.813 13.457 13.100 12.744

Feet/ Wrap

Air Gap Gap % 1100

2,155 2,117 2,078 2,040 2,001 1,962 1,924 1,885 1,846 1,808 1,769 1,730 1,692 1,653 1,615 1,576 1,537 1,499 1,460 1,421 1,383

Feet/ Layer

75.000 Wt.in H20

108.640 at 1.5% Ult.Stngth

108.500 & recalc. Deploy

1.220 0.016

37,151 34,995 32,879 30,800 28,761 26,760 24,798 22,874 20,989 19,143 17,335 15,566 13,836 12,144 10,491 8,876 7,300 5,763 4,264 2,804 1,383

Feet

ON

-4,995 -2,879

-800 1,239 3,240 5,202 7,126 9,011

10,857 12,665 14,434 16,164 17,856 19,509 21,124 22,700 24,237 25,736 27,196 28,617 30,000

Feet

OFF

Tai l Hold Line Pull Line Speed HPL Ratio

3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500

PULL, Lbs Tai l Hold

0.552 lb.

40,000 lb.

30,000 feet 3,500 lbf

30,000 lbf

100.000 ft/min

3.300

100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Ft/ Min

30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5

Meters/ Min

** 18 LAYERS

(Traction Output) (High Pull) (Traction Output)

330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00

Ft/ Min

100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6

Meters/ Min

-2,757 -1,589

-442

1,788 2,872 3,933 4,974 5,993 6,991 7,968 8,923 9,857

10,769 11,660 12,530 13,379 14,206 15,012 15,7C;;·

16,560

H20 Wt.

of Wire

<--------------------------STORAGE WINCH-----------------------------> <--- MAX PULL ---> ~-- LIGHT LINE --> 30,000 Lbs 9,091 Lbs

<------------ TRACTION WINCH ----------------->

AG24680.CHT

r

19 MAX

10 MID

Layer Number

\-8

MARKEY TRACTION & STORAGE WINCH DRUM CHART

MMCo Type DUTW·9·11 Done For AGOR24

Date = NOV 04, 93 Drive = HYD, 150 HP

** 48 CORE X 75 WIDE X 76 FLANGE DRUM

** 30,000 OF 0.680 FIB OPT

Cable Dia

19 Dia bQ,"el Dia Flng Dpth Act Layers

USE LAYERS

Layer Number

0.681 76.000 48.000 14.000 20.558

7S.921 74.559 73.197 71.835 70.473 69.111 67.749 66.387 65.025 63.663 62.301 60.939 59.577 58.215 56.853 55.491 54.129 52.767 51.405 50.043 48.681

Pitch Diam.

Fce Width Nom.Wraps enter· WRAPS

19.876 19.520 19.163 18.806 18.450 18.093 17.737 17.380 17.024 16.667 16.310 15.954 15.597 15.241 14.884 14.528 14.171 13.814 13.458 13.101 12.745

Feet/ Wrap

Air Gap Gap % /100

2,157 2,118 2,079 2,040 2,002 1,963 1,924 1,886 1,847 1,808 1,770 1,731 1,692 1,654 1,615 1,576 1,538 1,499 1,460 1,421 1,383

Feet/ Layer

75.000 Wt.in H20

108.480 at 1.5% Ult.Stngth

108.500 & recalc. Deploy

1. 112 0.015

37,163 35,007 32,889 30,810 28,769 26,767 24,804 22,880 20,994 19,147 17,339 15,569 13,838 12,146 10,492 8,877 7,301 5,763 4,264 2,804 1,383

Feet

ON

·5,007 ·2,889

·810 1,231 3,233 5,196 7,120 9,006

10,853 12,661 14,431 16,162 17,854 19,508 21,123 22,699 24,237 25,736 27,196 28,617 30,000

Feet

OFF

Tai l Hold Line Pull Line Speed HPL Ratio

3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500 3,500

PULL, Lbs Tai l Hold

< •••.•••••••••••• • ••••••••• STORAGE WINCH·····························>

AG24681.CHT

0.609 lb.

46,000 lb.

30,000 feet 3,500 lbf

30,000 lbf

100.000 ft/min

3.300

100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

Ft/ Min

30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5 30.5

Meters/ Min

** 18 LAYERS

(Traction Output) (High Pull) (Traction Output)

330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00 330.00

100 . 6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6 100.6

·3,049 ·1,759

·493

1,969 3,164 4,336 5,485 6,609 7,711 8,789 9,843

10,873 11,880 12,864 13,824 14,760 15,673 16,562 17,428 18,270

Ft/ Min

Meters/ H20 Wt.

Min of Wire

< ••• MAX PULL

30,000 Lbs

... > < .. LIGHT LINE .. >

9,091 Lbs

< •••••••••••• TRACTION WINCH ................. >

Layer Number

SECTION 2 - CONTENTS

Traction Winch svstem Operation

DESCRIPTION PAGE

1·. PLEASE READ! ......... ..................................... 2-1

2. WARNING! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -1

3. Before Starting The System .......... ; ...................... 2-1

4. Normal Operation ............. · ............................. 2-2 5.

6.

CAUTION! .........•...............•••...•......•........... 2-.--:;;

Emergency stop ............................................. 2-3 .- .

7. Traction Winch Manual Disk Brake ... ~ ...................... 2-3

8. Rigging The Traction Winch ................................ 2-~

9. Traction Winch Line Tension Wheel ............... . ......... 2-4- 10 . Traction Winch Sheave Rim Replacement ..................... 2-4

ll. Stowage Winch Manual Override ............................. 2-5

12. Stowage Winch Freewheel Clutch .................... . ....... 2-5

13. Stowage Winch Manual Disk Brake ........................... 2-5

14. Stowage Winch Level-Wind Setup ............................ 2- ._~ _ _ _

15. Stowage Drum Removal ...................................... 2-6

16. Stowage Drum Installation ............................... . . 2-6

17. Securing Wire to Stowage Drum ............................. 2-7

18. oil and Panel Heaters ..................................... 2-7

Drum J-Box, Cable Routing ...... ~ .......................... 2-8 Drum J-Box, Suggested Termination Method ................. . 2-9

19. Cable and Wire Spooling .... ................................ 2-10

20. System Set Up Controls .................................... 2-10 2l. Stowage Winch Tension and Mode Controls ................. . . 2-11 r-

(t:)y

2-1

SYSTEM OPERATION

1. PLEASE READ!

This section describes the operating procedures of the Markey DUTW-9-11 Research Traction Winch System. These procedures address the operation of the winch system only. Shipboard procedures may differ from these procedures to accommodate specific situations.

Always consult with the key shipboard winch operator regarding winch operations.

2. WARNING!

All winching and hoisting operations have inherent risks. Therefore, the safe operation of this product is dependent upon the operator's skill, knowledge and judgement. To avoid hazardous situations, operators must be familiar with all operating guidelines, safety codes, and regulations related to rigging, wire rope, and winch usage. Markey winches are not to be used to lift, support, or otherwise transport people, or loads over people.

The selected stowage winch tensions the line between it traction winch, automatically, when the hydraulic power started. All personnel must remain clear at start-up.

and the unit is

Never stand in or near the line of action. These areas present an extreme hazard to personnel.

3. BEFORE STARTING THE SYSTEM

It is intended that the mains disconnect on the HPU motor starter remain in the on position at all times. This will keep power to the heaters to reduce humidity, and avoid condensation in the electrical panels, local control panel, the HPU electric motor, and to maintain the hydraulic oil temperature at the 60 degrees F.

thermostat setting. A fourth position on the station select switch, "Standby/Heaters only", provides for energizing the heaters while disabling all other controls.

The entire "Before Starting The System" followed. Set up the system as follows:

procedure should be

A. Verify that there is power to the hydraulic power unit motor starter panel. If unsure, consult with the ship's engineer.

B. Check the heater switch well ahead of deployment time. If the switch is not on, turn it on and do not start the HPU until the oil temperature reaches 60 degrees F.

C. Select the load pin (and line lead). Note that selection of the system operating parameters is made at the System Interface Box, on the hydraulic power unit, in the winch compartment.

Select "Line Lead Aft" when the payload is to be deployed over the stern A-frame. This makes the aft leading flag block's load pin active so that line tension will be displayed. Either

0.680 inch diameter Signal Transmission Cable (coaxial type cable), Rochester No. A301241, or 9/16 inch diameter 3 x 19 MacWhyte Torque Balanced Wire Rope may be deployed over the

2-2 stern.

Select "Crane Line Lead" when the payload is to be deployed over the starboard "heavy-lift" crane. The crane base guide sheave's load pin will then be active and line tension displayed. Only the 9/16 inch diameter wire wire rope may deployed over the "heavy-lift" crane.

Verify that the load pin and line lead selected are correct for the required line lead. The selections are aft over the A-frame, or out over the starboard heavy lift crane.

D. Select the Stowage Winch to be active.

The 0.680 inch diameter Signal Transmission Cable is stowed on Stowage Winch #1 (port side).

The 9/16 inch diameter 3 x 19 Torque Balanced Wire Rope is stowed on Stowage Winch #2 (starboard side).

Verify that the stowage winch selected is the one whose cable or wire rope is actually rigged through the traction winch.

E. Select the control station to be active.

The traction winch system may be operated from any of its remote control stations

A fourth switch position, "Standby/Heaters Only", provides for energizing the heaters while disabling all other controls.

F. Verify that the stowage winch manual disk brake is released.

The hand pump is fully released when the pressure gauge reads zero.

G. Verify that the traction winch manual disk brakes are released.

The hand pump is fully released when the pressure gauge reads zero.

4. NORMAL OPERATION (AUTOMATIC MODE)

In the "auto" (automatic) . mode of operation the traction winch is directly controlled by the joystick, while the selected stowage winch is automatically controlled to maintain the correct speed, direction, and tension to spool the line onto the stowage drum. The mode of operation, automatic or manual, is selected inside the system interface box. This is a limited access area.

A. Single Lever Control: A single lever joystick controls the traction winch system to "Lower" or "Hoist" the payload, with the speed infinitely variable "0" to "Full Speed". The center position detent is "off" or "stop".

B. Control Sequencing: Start-up, normal shutdown, and emergency stop are all automatically sequenced to maintain control of the load by the traction winch system.

At start-up, the stowage winch first builds torque to provide c

2-3 the spooling tension and then releases it's auto-brake .

Second, the traction winch builds torque to support the load and then releases it's auto-brakes.

For both normal shut down, and emergency stop, the winches power down in the reverse order, with the traction winch auto brakes setting first.

C. Auto-Brakes: Bringing the joystick to neutral causes the auto-brakes to set when rotation slows to near stop.

The joystick may be moved from one quadrant directly to the other quadrant. The auto-brakes will not set so long as the joystick is not at neutral when rotation slows to near stop.

D. Manual Brakes: Both the traction winch and the stowage winches are provided with manual disc brakes. These brakes are individually actuated by hand pumps. Each hand pump is fitted with a pressure relief valve, pressure gauge, and a low-leakage release valve. The brakes are intended for short term use only .

5. CAUTION!: AVOID FAST STARTS OR SUDDEN CHANGES IN DIRECTION!

LINE OR EQUIPMENT DAMAGE COULD RESULT!

6. EMERGENCY STOP

In the event of a severe problem or emergency the traction winch system may be shut down by pushing the "Emergency stop" button on anyone of the traction winch control panels. This will result in an immediate, controlled shutdown. The traction winch system will stop hoisting or lowering, and the controls and the hydraulic power unit will be disabled.

If possible, it is advisable to slow the winch joystlck before pushing the emergency stop possibility of damage to the line - o~ equipment.

system with to minimize the the various unusual conditions will result in an automatic E-stop, such as an oil temperature gieater than 150 degrees F., or a pressure drop due to a stowage winch hydraulic hose burst.

To reset the system, resolve the problem that resulted in an E-stop, check to be sure the joystick is centered, twist the "Emergency stop" button toward "reset", and then- restart the hydraulic power unit. 'vV'/te.N/A/G. '

7. TRACTION WINCH MANUAL DISK BR~KE

DoN 01 A r/EM PI TiJ 'PLJJ1.1 P 13R{tk"ES /0 ).-1o~E IHI1N

3DOOPS/.

The traction winch drum manual disks brakes are used as "parking" brakes and for "emergency" use. The drum manual disk brakes are actuated by a hand pump located on the stowage winch base adjacent the drive assembly. The pump is provided with a gauge, a pressure relief valve set at 3000 psi, a low-leakage release valve, and a pump handle. Do not attempt to pump up the disk brakes to more than 3000 psi.

u

2-4

8. RIGGING THE TR~CTION WINCH

A. Remove the 4 guide pins from the traction winch.

B. Wire rope or cable may be stripped off the drum when the drum clutch is disengaged, or alternately, the servo-controls may be switched to "manual" to rotate the drum with the payout -or inhaul manual override knobs, and the traction drums with the joystick. The wire rope or cable is then pulled around the 6 grooves of the traction drums.

C. · When rigging the traction winch it necessary to remove all slack from the wraps around the traction winch to avoid slipping one traction drum, and possibly damaging the wire rope or cable. This insures that both traction drums rotate together in unison.

D. Reinstall the four guide pins. Notice that four long and one short guide pin and mounting bolt are supplied. The fifth guide and bolt set is mounted to the traction winch base on the starboard leg for "safekeeping".

E. When the starboard stowage winch is rigged, install the short guide pin and bolt at the lower starboard side of the traction winch.

F. When the port stowage winch is rigged, install the short guide pin and bolt at the upper port side of the traction winch.

9. TRACTION WINCH LINE TENSION WHEEL

which contacts of the sixth between the even in the

The traction winch is fitted with a pressure wheel the wire rope or cable, at the exit tangent point groove. This pressure wheel causes the line tension traction winch and a stowage winch to be maintained, absence of a payload on the line.

When access is required for rigging the traction winch:

A. Turn off the hydraulic power unit.

B. Back off .the spring adjustment nut and move the pressure wheel for access to the sheave grooves .

c. Rig the wire.

D. Tighten the spring adjustment nut until the spring is 7-3/8 inches high.

10. TRACTION WINCH SHEAVE RIM REPLACEMENT

The traction winch features one-piece bolt-on, heat treated , replaceable sheave rims. The rims have 6 grooves and are sized for

0.680 inch diameter coaxial cable. 9/16 inch diameter 3 X 19 torque bala~ced wire rope may be run in the same grooves. To replace a rim:

t.AUT/Df\J: RIM uJE)Gt/S ?ODl.--3SJ U.5E A..sulT/16LE l.-IFTiNG J::>cL-(/~E A. Carefully support the weight of the rim, they weigh 800 Ibs each, approximately .

B.

c.

D.

2-5

Remove the 30 lug nuts fastening the rim to it's hub, and remove the rim .

Replace the rim and reinstall the 30 lug nuts hand tight.

Torque the lug nuts to 450 to 500 Ib-ft dry, Ib-ft lubricated with an anti-seize compound.

the hub to rim mating surfaces. Torque the lug pairs until all are torqued. Initially torque 50 Ib-ft, and then all in 100 Ib-ft increments torque is reached. Do not over torque.

or 350 to 400 Do not lubricate nuts in opposing all lug nuts to until the final

11. STOWAGE WINCH MANUAL OVERRIDE

The stowage -winch may be operated in a the traction winch for spooling and selected stowage winch is manually systems interface box on the HPU.

manaul mode, independent maintenance purposes.

controlled from inside of The the stowage winch control mode, spooling tension, speed, and direction controls, and a tension display are all located on the panel inside the system interface box, behind the locked door on the hydraulic power unit.

The traction winch remains directly controlled by the joystick when in the manual mode.

r 12. STOWAGE WINCH FREEWHEEL CLUTCH

A drum freewheel clutch is provided to disconnect the drum from the hydraulic motor and auto-brake. This feature may be used for de-spooling wire, with the drum brake providing some line tension as required. The drum clutch is actuated by a hand pump located on the stowage winch base adjacent the drive assembly. The pump is provided with a gauge, a pressure relief valve set at 500 psi, a low-leakage release valve, and a pump handle. Do not attempt to pump up the clutch to more than 500 psi. To operate the freewheel clutch:

A. Line tension between the traction winch and stowage winch must be released to disengage the freewheel clutch. To release the line tension, turn HPU power on, and then manually offset the auto-brake release valve with a pointed object until the drum rotates slightly.

B. Pump up the freewheel clutch to at least 350 psi to fully release it.

c. Use the manual disk brake to control the line tension.

WI1I(.N/AJG-: bo NOT ATTEIt,PT Ii) fL'trIp

13. STOWAGE WINCH MANUAL DISK BRAKE vf bJ~f< -g~Ak:'E Mo1€.€ /'HA!\f

;)..0 DO PS I

The drum manual disk brake, one located on each stowage winch, is used as - a "parkingll brake and to tension the wire rope or cable during de-spooling. The drum manual disk brake is actuated by a hand pump located on the stowage winch base adjacent the drive assembly .

The pump is provided with a gauge, a pressure relief valve set at 2000 psi, and a low-leakage release valve. A pump handle is stored adjacent the drum clutch and disk brake pumps . Do not attempt to

2-6 pump up the disk brake to more than 2000 pSl.

~ 14. STOWAGE WINCH LEVEL-WIND SETUP

The stowage winch level-winds are configured for adjustment of the fairleaders without disconnecting them from the fairlead drive, and with enough mechanical advantage to adjust against the maximum spooling line tension. The_ adjustment handwheel, normally stationary while the winch is in operation, is disengaged from the brake jaw and rotated to advance or retard the levelwind. This is accomplished by:

A. Loosen the fluted brass knob which retains the handwheel.

B. Pull the handwheel outward until it is free of the brake "jaw" .

C . Rotate the handwheel toward advanc~ or retard the levelwind.

15.

A.

B.

C.

D.

E.

F.

The levelwind is normally adjusted so that the wire or cable lags 1/2 to 1 wire diameter behind the current wrap.

0. A- vl(j)N~ c..orvuo ItVe..JJ /'VelG-H T of 1J RUM (~ STOWAGE DRUM REMOVAL - WI/( E' / S .;l.,~/ 000 I- 35· USE 11

:5 u,. '/1tJ3LE: 1.-/ 1=17 /\/G . De. VI C.-E? ., Support the drum and wire. The combined weight is approximately 22,000 lbs.

Disconnect the signal cable connector from the slip ring unit .

Remove the slip ring unit to avoid possible damage.

Remove the first stage fairlead chain guard and drive chain .

Remove the outboard bearing cap and bolts. Do not remove the oil filled bearing cartridge from the drum shaft. It may remain in place.

Remove the nine 1"-8NC x 3" bolts connecting the drum to drive disc. Notice that a tapered alignment pin occuples tenth hole.

the the

G. Install two 11l-8NC x 411 hex. head jacking bolts in the drive disc. Tighten the bolts to jack the drum from the drive disc.

H. Hoist the drum and wire clear of the stowage winch base.

16. STOWAGE DRUM INSTALLATION

A. Slide the outboard bearing cartridge toward the drum.

B.

C

Position the drum and wire in the stowage winch base, bearing cartridge in the bearing block and with the dowel in place.

with the alignment

Release the freewheel clutch to rotate the drive disc into alignment with the drum bolt holes .

D. Start the drum onto the alignment stud and the pilot diameter .

E. Reinstall the nine 1"-8NC x tight against the drive disc.

Torque Table page 4-10.

3" bolts to pull the Torque the bolts per the

2-7 drum Bolt

F. Reinstall the outboard bearing cap and bolts. Torque the bolts per the Bolt Torque Table 4-10.

G. Reinstall the first stage fairlead chain guard and drive chain.

H. Reinstall the slip ring unit.

I. Reconnect the signal cable connector to the slip ring unit.

17. SECURING WIRE TO STOWAGE DRUM

A. Wire Rope: Pass the wire rope inward through the pass-thru slot in the drum shell and secure it in the clamp block. Leave 2 inches of wire extending through the clamp block.

B. Electromechanical Cable: Pass the 0.680 diameter E.M. (coaxial) cable through the pass-through slot in the drum shell, through the clamp block, and make one extra turn around the drum shaft, just inward of the drum shell, across the end diaphragm gussets, securing the cable to the end diaphragm as required, and then passing it through a wire grip or stuffing tube into the drum junction box. The extra cable turn provides for re-terminating the cable at a later date.

The slip ring pigtail cable is passed inward through the hollow drum shaft, back through the drum end diaphragm to the outside, and into the drum junction box. Access holes through the end diaphragm to the drum interior are provided.

Refer to the illustrations on pages 2-8 and 2-9.

18. OIL AND PANEL HEATERS

Heaters are provided to keep the hydraulic oil up to the minimum operating temperature of 60 degrees F., and to raise the interior temperature of the motor starter panel, the system interface box, and the local control enclosure to reduce humidity, and avoid condensation and corrosion.

All heaters are activated by the heater switch on the starter panel door, and thermostatically controlled to 60 degrees F.

The mains disconnect switch on the starter panel door disconnects all heaters.

also

It is recommended that the mains disconnect and the heater control switch remain on at all times.

A fourth position on the station select switch, "standby/Heaters ~ Only", provides for energizing the heaters while disabling all other controls.

CABLE "PIG TAIL"

CLAMP AS REQUIRED

ACCESS COVER

(3) PLACES

DRUM J-BOX

CABLE ROUTING

TO DRUM J-BOX

CABLE ENTRY SLOT

"PIG TAIL" PASS-THRU

0 . 680 DIA . E.M . CABLE

(COAXIAL CABLE)

CABLE CLAMP

~ EXTRA LOOP OF

CABLE, CLAMP AS

REQUIRED

--r-f.- "p I G TA I L" CABLE

PASSES THRU HOLLOW

DRUM SHAFT TO

SLIP RINGS

SEATTLE [~) WASH .

DRUM J-BOX

0.680 E.M . CABLE

,REV

.- - --.. iii CATE 06,1 ~/.~

BY RI'o\l

I:: '5J6~jBII B 2- I

SCALE I I/Z _I U

f\)

E.M . CABLE (COAXIAL)

CONDUCTOR & INSULATOR

SLEEVED TO TERMINAL

CABLE PIG TAIL

(TO SLIP RINGS)

WATERTIGHT CABLE GRIPS~

OR STUFFING TUBES

USER SUPPLIED

ARMOR CONNECTION -

SLEEVED

600 V RATED

TERMINAL BLOCK

NEMA 4X ENCLOSURE /

FIBERGLASS, LEXAN

WINDOW OPTIONAL

RETURN TWISTED-~

& SLEEVED

STANDOFF INSULATOR

INDOOR RATINGS

5000 V

4.8 KVA

SPACER

4 PLACES

tD

I v

N

I o tD

I , NOTE :

I. TERMINATIONS TO BE MADE BY

USER TO THEIR SPECIFICATIONS .

2 . STUFFING TUBES OR CABLE GRIPS

TO BE SUPPLIED BY USER .

SEA TTLE [MARKEY 1 WASH .

DRUM J-BOX

0.680 E.M. CABLE

SUGGESTED TERMINATION METHOD

DRUM J-BOX

, 1 . ... 1"". i i L DAT[ 08/IC.f.~

BY R'M;

l:lE ~6.:~7'0. I B I' B 2 - 2

EV

N , 2-10

19. CABLE AND WIRE SPOOLING

MMCo. experience with many winches aboard UNOLS and other research vessels indicates that excellent spooling can be expected with the

0.680 diameter coaxial cable. The 9/16 inch diameter torque-balanced 3 x 19 wire rope due to it's "triangular" cross section has a history of requiring greater spooling attention.

It is expected then that the 9/16 3 x 19 will always need to be closely monitored while being brought back aboard, and "helped" as is needed to achieve good orderly spooling.

The suggested spooling tension for handling the 9/16 3 x 19 wire is 3000 lbf. .

It is MMCo's experience that coaxial cable spools well at 2000 lbf.

20. SYSTEM SETUP CONTROLS

The system setup controls, located on the front of the systems interface box door, are as follows:

A. Load Pin/Line Lead Select:

"Aft Line Lead" is selected when the line lead is aft through the flag block and over the A-frame sheave. This line lead will handle either the 0.680 inch diameter coaxial cable or the 9/16 inch diameter 3 x 19 wire rope.

"Crane Line Lead" is selected when the line lead is through the guide sheaves and up through the crane base. This line lead is dedicated to the 9/16 wire rope.

B. Stowage Winch Select

"#1 Stowage Winch" is selected when the cast will use the 0.680 inch diameter coaxial cable.

"#2 Stowage Winch" is selected when the cast will use the 9/16 inch diameter 3 x 19 wire rope.

C. station Select

"Standby, Heaters Only", position provides power to the heater circuit while disabling all controls on all three control stations.

Additional positions are utilized to select the specific control station for operating the traction winch .

When a specific operating station is selected, all other control stations are disabled, except for the emergency stop pushbuttons which remain active.

2-11

21. STOWAGE WINCH TENSION AND MODE CONTRLS

The stowage winch tension and mode controls, systems interface box door, are as follows:

located inside the

A. "Inhaul Tension Adjustment" (#1) adjusts the automatic mode inhaul spooling line tension from approximtely 1000 Ibf. to approximately 3500 Ibf. This is done with the HPU running, the mode select switch (#2) in auto, and the joystick in slow inhaul.

B. "Mode Select" (#2) selects the "manual" or "auto" mode. In the "auto" (automatic) mode the spooling tension is maintained regardless of line speed, overboard line load, or wrap layer on the stowage drum. The stowage winch speed is automatically sychronized with the joystick and the traction winch.

In the "manual" mode the stowage drum speed is manually controlled by the manual speed control (#4), and independent of the traction winch and the joystick. Spooling line tension is not controlled in the "manual" mode.

CAUTION:

suspended load.

Changing to the "manual" mode while a load on the line could result in loss of control of is the

CAUTION: Check for slack line between the stowage and traction winches. Use the "manual" mode to take up slack before startup.

CAUTION: The "auto" mode causes the line to be tensioned automatically at startup.

CAUTION: The selected stowage winch will rotate continuously in the inhaul direction in the "auto" mode without line tension.

CAUTION: The manual direction selector switch (#3) must be in the "auto" position when the mode is changed at switch #2.

C. "Manual Direction Select" (#3) determines the stowage winch direction of rotation, "inhaul", "auto", or "payout", in the manual mode only. Return switch #3 to the "auto" position when switch #2 is in the "auto" position.

CAUTION: The manual speed control (#4) must be at "0" before "inhaul" or "payout" are selected.

D. "Manual Speed Control" (#4), in the "manual" mode varies the rotational speed of the stowage winch selected, for the direction selected at the manual direction select switch (#3).

Always return the speed control to "0" when returning to the "auto" mode.

Use the "manual" mode to take up slack between the stowage and traction winches.