Teledyne Oceanscience rapidCAST User Manual
Information included herein is controlled by the Export Administration Regulations
(EAR) and may require an export 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 prohibited.
rapidCAST™
User’s Guide
P/N 95J-8000-00 (March 2018)
© 2018 Teledyne Oceanscience, Inc. All rights reserved.
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TABLE OF CONTENTS
INTRODUCTION .................................................................................................................................................1
RAPIDCAST OVERVIEW.......................................................................................................................................3
Terminology ................................................................................................................................................. 4
Mechanical Requirements ........................................................................................................................... 6
Electrical Requirements ............................................................................................................................... 8
Power Connectors ................................................................................................................................ 8
Power Cable Connections .................................................................................................................... 9
Performance Specifications and Operational Limits .................................................................................... 11
INSTALLATION ...................................................................................................................................................14
Unpacking the rapidCAST system ................................................................................................................. 15
Safety ........................................................................................................................................................... 15
Important Safety Warnings .................................................................................................................. 15
Important Deployment Warnings ........................................................................................................ 16
Lockout Procedure ............................................................................................................................... 16
Installing the rapidCAST Interface Software ................................................................................................ 16
Software Architecture .......................................................................................................................... 17
A Tour of the RapidCAST Interface ....................................................................................................... 17
Cable Connections........................................................................................................................................ 18
Antenna Position .......................................................................................................................................... 22
Switch Functions .......................................................................................................................................... 23
LED Functions ............................................................................................................................................... 24
Installing the 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 Properties ..................................................................................................................................... 30
Line Routing Procedure ........................................................................................................................ 31
Installing and Connecting the Probe .................................................................................................... 32
Installing the Probe Software ....................................................................................................................... 33
Verifying Probe Communications ................................................................................................................. 33
INITIAL SETUP ...................................................................................................................................................35
Power up Sequence ..................................................................................................................................... 36
Connecting the Winch to a PC ...................................................................................................................... 36
Verifying Basic Motion Functionality ........................................................................................................... 37
Adjusting the LevelWind Position ................................................................................................................ 38
Line Management ................................................................................................................................ 39
Checking for Line Fouling ..................................................................................................................... 39
Defining Positions ........................................................................................................................................ 40
Setting the Home Position ........................................................................................................................... 40
Dock Position........................................................................................................................................ 41
Comm Position ..................................................................................................................................... 42
Launch Position .................................................................................................................................... 43
Recovery Position ................................................................................................................................. 43
Saving and Loading Workspaces .................................................................................................................. 45
CURVE FITTING & DIVE TABLE CREATION .................................................................................................................47
Using Auto-Depth ......................................................................................................................................... 48
What Auto-Depth Does and Does Not Do ............................................................................................ 48
Auto-Depth Customizable Parameters ................................................................................................. 49
Auto Depth Status ................................................................................................................................ 50
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Using Coverage ............................................................................................................................................ 50
Using Auto-Repeat ....................................................................................................................................... 51
PERFORMING YOUR FIRST CAST ............................................................................................................................52
Step 1 –Setup ............................................................................................................................................... 53
Step 2 – Set Target Depth ............................................................................................................................ 53
Step 3 – Set Parameters ............................................................................................................................... 54
Step 4 – Move to Point Launch .................................................................................................................... 55
Step 5 – Tension Controlled Payout ............................................................................................................. 56
Step 6 – Move to Point Recovery ................................................................................................................. 57
Step 7 – Move to Point Comm ..................................................................................................................... 58
Complete ...................................................................................................................................................... 58
DISASSEMBLY AND PACKING .................................................................................................................................60
USING THE CONFIGURATION SETTINGS ....................................................................................................................61
RESOLVING FAULT CONDITIONS .............................................................................................................................62
TENSION ARM CALIBRATION .................................................................................................................................69
USING THE GUI WINDOWS AND CONTROLS .............................................................................................................72
UPDATING THE WINCH SOFTWARE .........................................................................................................................74
MAINTENANCE PROCEDURES ................................................................................................................................75
Tailspool ....................................................................................................................................................... 76
Shackle Replacement ................................................................................................................................... 78
Loop Splice ................................................................................................................................................... 79
Inline Splice .................................................................................................................................................. 80
Replacing the Spool ...................................................................................................................................... 80
Removing the Spool ............................................................................................................................. 80
Reassembling 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. Probe Assembly Overview .......................................................................................................... 6
Figure 5. Cable Clearance Requirements .................................................................................................. 7
Figure 6. Mounting Requirements ............................................................................................................ 7
Figure 7. Power Cable Connections ........................................................................................................... 9
Figure 8. 7000625 Cable Plug/Termination ............................................................................................... 9
Figure 9. 60309 Vessel Socket / Receptacle/ Outlet ................................................................................. 9
Figure 10. 7000652 Cable Plug/Termination ............................................................................................. 10
Figure 11. Vessel Socket/Receptacle/Outlet ............................................................................................. 10
Figure 12. Removing the Winch Assembly Covers .................................................................................... 19
Figure 13. Winch Assembly Connectors .................................................................................................... 19
Figure 14. rapidCAST Cable Connections (Large Vessels) .......................................................................... 20
Figure 15. rapidCAST Cable Connections (Small Vessels) .......................................................................... 21
Figure 16. Omni Antenna .......................................................................................................................... 22
Figure 17. Patch Antenna .......................................................................................................................... 22
Figure 18. Control Module ........................................................................................................................ 23
Figure 19. Interface Module ...................................................................................................................... 23
Figure 20. Center of Mass (CM) Location .................................................................................................. 26
Figure 21. Attaching Pipe Mount .............................................................................................................. 27
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Figure 22. Pipe Mount Installed on UCTD Adapter Plate .......................................................................... 27
Figure 23. Installing the Winch on the Pipe Mount ................................................................................... 28
Figure 24. Mounting the Control Module ................................................................................................. 29
Figure 25. Control Module Dimensions ..................................................................................................... 29
Figure 26. Line Routing Procedure ............................................................................................................ 31
Figure 27. Installing the Probe .................................................................................................................. 32
Figure 28. Assigning the COMM Ports ....................................................................................................... 36
Figure 29. Jog and Teach Tab .................................................................................................................... 37
Figure 30. LevelWind Adjustment ............................................................................................................. 38
Figure 31. Line Management .................................................................................................................... 39
Figure 32. Dock Position ............................................................................................................................ 41
Figure 33. Comm Position ......................................................................................................................... 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 Calibration ........................................................................................................... 71
Figure 40. Bad shackle ............................................................................................................................... 76
Figure 41. Good Shackle ............................................................................................................................ 76
Figure 42. Bad Loop splice, worn and torn ................................................................................................ 76
Figure 43. Good Loop Splice ...................................................................................................................... 76
Figure 44. BAD Inline Splice ....................................................................................................................... 77
Figure 45. Good Inline Splice ..................................................................................................................... 77
Figure 46. Shackle Replacement ............................................................................................................... 78
Figure 47. Loop Splice ............................................................................................................................... 79
Figure 48. Inline Splice .............................................................................................................................. 80
Figure 49. Removing the Encoder ............................................................................................................. 81
Figure 50. Removing the Spool ................................................................................................................. 81
Figure 51. Spool Retention Points ............................................................................................................. 82
Figure 52. Spool Installed .......................................................................................................................... 82
LIST OF TABLES
Table 1. rapidCAST Depth versus Speed ................................................................................................ 12
Table 2. Inventory .................................................................................................................................. 15
Table 3. Spare Parts Kit 71JK6004-00 ..................................................................................................... 75
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REVISION HISTORY
March 2018
• Added Depth versus Speed table to specifications.
February 2018
• Added the Export Administration Regulations (EAR) statement
• Corrected inventory list part numbers
• Corrected part number for shackle on Figure 46
March 2017
• Updated the Lockout procedure
• Updated the RapidCAST Interface tour
• Updated Maintenance procedures with table showing the spare parts kit 71JK6004-00
• 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 calibration
May 2016
• Updated manual to include changes from rapidCAST Interface software version 1.5.1
• Added Line Properties, Line Management, and Checking for Line Fouling sections
• Updated Adjusting the LevelWind Position
• Updated the Profiling Capability specification from 500m at 8 kts to >500m at 5 kts
• Updated phone numbers
April 2016
• Revised most assembly drawings and figures.
• Updated Resolving Fault Conditions
• Added Appendix A – Installation Drawings
September 2015
• Initial release.
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NOTES
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Page 1
Introduction
Dear Valued Customer,
Thank you for purchasing your rapidCAST
TM
system. Teledyne Oceanscience has a support team in place
to assist you with understanding, operating, and deploying your rapidCAST system. Included with your
system is documentation regarding the setup and deployment of the rapidCAST. We strongly encourage
you to thoroughly read through this documentation to maximize your user experience.
T ECHNICAL S UPPORT
If you have technical issues or questions involving a specific application or deployment, contact:
Phone: +1 (858) 842-2600
FAX: +1 (858) 842-2822
Email: Oceanscience.Support@teledyne.com
If you have technical issues or questions involving a specific application or deployment with your instru-
ment, contact our Field Service group:
S ALES
Our products are available from Oceanscience directly or from representatives throughout the world.
Please contact us for more information:
E-mail: Oceanscience.Sales@teledyne.com
V IDEOS
Additional training support is available via videos:
• Overview and Deployment
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The rapidCAST delivers a probe to a user-specified target depth while the vessel is underway, and retrieves the probe automatically. Using an entirely new active tension management system, payout behavior is precisely controlled to ensure the probe depth is known at all times - even without a conducting cable! Data transfer is achieved using 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 tension is measured in real-time, and the rotation speed of the spool is quickly modulated
to minimize tugging on the probe.
• If tension rises above the setpoint, the spool speeds up, and if tension falls below the setpoint,
the spool slows down until equilibrium is restored.
• The Tension Control System prevents the ship from dragging the probe, and ensures that the
probe falls freely despite surface disturbances such as waves, swells, heaving, pitching, and rolling.
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rapidCAST Overview
THE RAPIDCAST OVERVIEW INCLUDES THE FOLLOWING:
Terminology
Mechanical Requirements
Electrical Requirements
Performance Specifications and Operational Limits
COMM
LaunchRecovery
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Terminology
Use this section to learn the terms that will be used throughout the manual.
Figure 1. Winch Assembly Overview
Figure 2. Interface Module Overview
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Figure 3. Control Module Overview
• The top four connectors 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!
• Connectors circled in red are used only in special circum-
stances and are normally left disconnected. Make sure the
caps are on during a deployment to protect the connectors.
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Figure 4. Probe Assembly Overview
Mechanical Requirements
Mounting Requirem ents: The ideal deployment location is in the center of the vessel, with deployment directly over the aft rail, but other locations may be possible. The swivel base should be mounted
within 24 inches of the aft rail. Oceanscience can provide designs for mounting options if necessary. Installation of a serial cable running from the rapidCAST electronic control module to the survey PC is required. As the probe uses wireless Bluetooth telemetry, no cabling is required for data download.
The figure below depicts mounting and cable clearance requirements. Routing of the winch power and
data cables must be taken into consideration. The bolt circle should be oriented as shown below because
the swivel base has built in stops to control the rotation of the winch, see Figure 6. The mounting platform
should be able to withstand a moment of 70ft-lbs with little to no deflection. Below the mounting platform, a 3.0 inch clearance is required for cable routing. Straight down cable routing is shown in RED.
Sideways cable routing is also possible if there is a minimum 3.0 inch clearance, shown in BLUE.
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Figure 5. Cable Clearance Requirements
Figure 6. Mounting Requirements
See Appendix A - Installation Drawings for a detailed Pipe Mount Installation Drawing.
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Profiling Depth: The nominal specification is 500m at 8kts, which requires ~1500m of line. As the vessel speed decreases, the achievable cast depth increases up to the maximum pressure rating of the probe
for long stationary casts. As very deep casts are much longer in duration, the vessel cannot be moving appreciably as this will waste available line to account for the movement of the ship. As the vessel speed increases above 8kts, the achievable depth decreases to maintain the profiler in a safe condition during recovery (low line tension). The maximum vessel speed under normal operation is 12kts. The motor rpm
and braking time may be adjusted by the user to suit the survey conditions.
As long as the vessel retains a nominal forward motion to prevent entangling of the line in the ship propeller. 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 breaking strength with an 800lb leader.
Line Length: The maximum amount of line that can be loaded is about 3000m. Typically, 1500m is
used. Line length does not directly correlate to maximum cast depth underway. This depends on ship
speed because the total line paid out is a product of ship movement and probe depth.
Electrical Requirements
Input Voltage: 90 — 264 VAC RMS, Single Phase
Input Frequency 47 — 63 Hz
Max Current (at 115 VAC Input): 16 A
Max Current (at 230 VAC Input): 10 A
Inrush Current (Cold Start): 50 A Typical
Power Connectors
The rapidCAST system ships with 2 power cables, offering flexibility in the connectors used for power.
• Part Number 7000625 - 100-ft Power Cabl e Ter m inated with IEC 60309 250V 16A, 6H, Blue
P+N+E Plug, that mates to IEC 60309 250V 16A, 6H, Blue P+N+E Socket
• Part Number 7000652 - 5-ft Cable Adapter Terminated with NEMA 5-15P Plug, that mates to
NEMA 5-15R Receptacle
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Power Cable Connections
The diagram below shows how the power cables may be connected.
Figure 7. Power Cable Connections
Figure 8. 7000625 Cable Plug/Termina-
tion
Figure 9. 60309 Vessel Socket / Recepta-
cle/ Outlet
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Figure 10. 7000652 Cable Plug/Termination Figure 11. Vessel Socket/Receptacle/Outlet
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Performance Specifications and Operational
Limits
Winch Length 48cm (18.89”)
Length with Davit 200cm (78.74”)
Width 71cm (27.95”)
Height 46cm (18.11”)
Weight 36kg (79.36 lbs.)
Input Voltage 48 VDC/ 2.0 kW
Line Capacity 3000m
Construction Aluminum/Delrin/Titanium/Stainless Steel
Probe Recovery Speed 0.5-2m/s (1.5-6.6 fps)
Mount Swivel base (12cm diameter)
Hardware Stainless 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 1.18kg (2.6 lbs.)
Valeport rapidSV Probe Length (with tail spool) 111cm (43.70”)
Diameter 5cm (1.96”)
Weight (in air) (without tail spool) 4.48kg (9.87 lbs.)
Internal Memory 1000 casts
Depth Rating 2000m
Pressure Resolution ±0.001% range
Accuracy ±0.05% range
Range 0-200 dBar
Temperature (if fitted) Resolution 0.001C
Accuracy ±0.01C
Range -5 to 35C
Sound Velocity Resolution 0.001m/s
Accuracy ±0.02m/s
Range 1375 - 1900m/s
Profiling Capability >500 m at 5 kts or deeper at slow speeds
(see Table 1, page 12)
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Table 1. rapidCAST Depth versus Speed
The table above applies to the RapidSV probe. Call for details on other probes.
Each standard spool is delivered with 1954 meters of line, of 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 this configuration, the probe will fall at approximately
3 m/sec.
The following general specification applies:
• Boat speed relative
Deployment greater than 100 meters deep:
• The buoyancy tailspool CANOT be used. In this configuration use the plain tailspool, the probe
will fall at approximately 4 m/sec.
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Quick Review
Check that you know the
Terminology used.
Reference Figure 1 through
Figure 4.
Check that the boat meets
the Mechanical and
Electrical Requirements
Reference page 6 to 8.
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Installation
I NSTALLATION INCLUDES THE FOLLOWING STEPS:
Unpacking the rapidCAST system
Installing the RapidCAST Control Software
Learning Cable Connections and Switch Functions
Mounting the Winch
Verifying Probe Communications
COMM
LaunchRecovery
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Unpacking the rapidCAST system
Included with the rapidCAST:
Table 2. Inventory
Packed in
transit case:
Part Number Description Quantity
6001752:
CASE,
TRANSIT,
RCAST,
WINCH
6001417 ASSY, WINCH, RAPIDCAST 1 ea
7000625 CABLE, AC POWER, RCAST, 30.5M 1 ea
7000652 CABLE, AC POWER, RCAST, 1.5M 1 ea
75JK6001-00 Documentation kit contains the RapidCAST Interface software program, USB RS-485
Driver, manuals, and backup driver software.
1 ea
9002211 CABLE, RF, TNC STRAIGHT PLUG, LMR400, 40M 1 ea
9002104:
CASE,
TRANSIT,
RCAST, DAVIT
71J-5001-00 ASSY, DAVIT, RCAST, W/PULLEY 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, PIPE FLANGE, RCAST 1 ea
6001436 ASSY, PROBE BRACKET, RCAST 2 ea
6001751 KIT, TOOLS AND SPARES, RCAST 1 ea
7000650 CABLE, TELEMETRY AND CONTROL, RCAST 1 ea
6000617 SET, TAILSPOOL W/BULKHEAD, RCAST/UCTD 1 ea
6000630 SET, TAILSPOOL W/BULKHEAD, RCAST/UCTD, W/BUOYANCY MODULE 1 ea
8000112 TRAINING PROBE, RCAST/UCTD 1 ea
9002212 CABLE, RF, TNC STRAIGHT PLUG, LMR400, 5M 1 ea
9002173 ANTENNA, 2.4 GHz 8dBi FLAT PATCH W/ TNC CONNECTOR 1 ea
Safety
Important Safety Warnings
Do not put your hands inside the frame unless the system is Locked Out.
Always assume the system is live.
When in doubt use Emergency Stop.
Stand clear of line, do not stand in loops or wrap line around your hand.
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Important Deployment Warnings
Never go past the maximum line payout.
Line is taped on the spool. Never get in to the bottom RED layer or you will lose a probe.
If the winch cannot pull the line in or the brake is not working, STOP the vessel immediately.
Lockout Procedure
To lock out the system:
1. Switch Motor Driver OFF.
2. Switch Brake to RELEASE.
3. Check to ensure Activity Light is Dim/Not blinking.
4. Check to see if the spool rotates freely.
The system is now SAFE.
Installing the rapidCAST Interface Software
The rapidCAST Control Software 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 U S B por t of Ra pid CA S T Interface Module, which should automatically install two USB Serial Port devices on the PC.
Make note of the serial port numbers because they will be used for:
Lower Comm port for Telemetry
Higher Comm port for Control
2. Install the USB RS-485 Driver located in the 1 – Required – USB RS-485 Driver folder of the documentation CD, specifically the RS-422/485 USB Adapter.
3. Install the RapidCAST Interface software by double-clicking on the RapidCAST
Interface X.xx.exe file (where X.xx is the version number) located in the 2 – Required – RapidCAST Interface X.xx folder. Administrator access is required to
properly install the software. A desktop icon is added: Double-click to run the
software.
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Software Architecture
RapidCAST encompasses 2 types of software: RapidCAST Motion and RapidCAST Interface.
• RapidCAST Motion is firmware that resides inside the Control Module, responsible for real-time
motion control and winch operation. It exposes a text-based interface that allows the winch to be
controlled via string messages. Due to the large number of messages required, however, users do
not interact directly with RapidCAST Motion. When new functionality is introduced through future software releases, RapidCAST Motion can be upgraded in the field (see Updating the Winch
Software).
• RapidCAST Interface is a graphical user interface that runs on a PC and is the primary method for
operating the winch. It functions as a messaging and task management layer that transmits commands to RapidCAST Motion, hiding the latter’s complexity behind a friendly and intuitive graphical interface.
As needs arise, Teledyne Oceanscience may modify or upgrade either software independently of the other.
Because of their message-based infrastructure, RapidCAST Motion and RapidCAST Interface must have
the same Compatibility Group to ensure proper function. A Compatibility Group is simply a number that
identifies whether a particular version of RapidCAST Motion or RapidCAST Interface are “speaking the
same language” and are therefore fully compatible.
The About window (see Using the GUI Windows and Controls) identifies the software versions on the
Control Module and on the PC, as well as their respective Compatibility Groups. If there is a mismatch,
the About menu 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 RapidCAST Interface
The Dashboard is the top panel and gives the operator a snapshot of the winch’s health and current state.
Important information such as the spool’s speed and rotation direction, the power-supply voltage, and
brake status are reported here. The Dashboard keeps the user informed of the system’s critical operating
parameters.
The Task Bar is the second section. It reports the winch’s current assigned task and provides a progress
estimate.
The bottom panel is the Tab Group, which is a collection of tabbed windows grouped according to common functionality. The Tabs are organized as follows:
• Deployment: Allows the user to set deployment depth, as well as monitor and control an auto-
mated deployment.
• Dive Table: Identifies the dive table used to calculate the Tension-Controlled Payout duration
from a target depth. Allows the user to define the polynomial coefficients of additional dive tables
and switch between them.
• Jog and Teach: Allows the user to jog (move) the winch as well as define positions.
• Winch Config: Allows the user to modify advanced operating parameters.
• Maintenance: Contains a grouping of varied tasks associated with system maintenance and atypi-
cal activities such as software updates and health logging.
A Gauge Cluster on the left provides a graphical representation of the Tension Arm position as well as the
spool’s speed and rotation direction. When the Tension Arm is at its lowest position, the angular gauge in
the Interface Software should show the Tension Arm pointing at the far edge of the red zone. If the Tension Arm is not depicted at this position when the arm is fully relaxed, calibration is needed (see Tension
Arm Calibration).
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The spool indicator shows the speed of the line out (blue) and line in speed (yellow). The two white circles
represent the LevelWind position, and blink when the LevelWind is at the full left/right positions.
Line Out - Calculating the length of line paid out depends on how tightly the spool is packed, as well as
the amount of line loaded on the spool (both of which affect the spool’s effective circumference – an important variable when calculating line length). The spool’s circumference decreases as more line is paid
out, and though this behavior has been mathematically modelled as part of the line-length calculation, the
values given by the Line Out display should still be treated as an approximation. 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 controller. This value will increase or decrease depending on the load applied to the motor. Note: Motor will shut down at 70C.
Supply voltage: Indicates the state of the 48V supply, which powers the Spool Motor.
Cable Connections
The system is shipped with the winch end of the cables pre-connected for ease of installation.
The following is for reference.
To remove the covers (only necessary if cables are not connected on the winch end):
1. Remove the covers on the winch assembly.
2. First, remove the four (4) screws and flat washers on the top cover. Slide the top cover toward the
rear of the winch to remove it.
3. Remove the fours screws and flat washers on each side cover and slide the cover down, and then
pull the bottom handle to release the bottom bracket.
4. Next, slide the cover up and pull out slightly to remove it.
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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 connector 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.
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4. Connect the Tension cable between the Control Module and Winch. The Tension connector is located under the belt side cover.
5. Connect the LevelWind PROX sensor cables between the Control Module and Winch. The LevelWind1 connector is located under the motor side cover; the LevelWind2 connector is located under the belt side cover.
6. Use Figure 12 to re-install the winch assembly covers.
7. Connect the Control cable 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 14). Alternately, you can connect the
Omni antenna directly to the Interface Module and omit using the 9002211 cable (smaller vessels
use Figure 15).
9. Connect the AC power cable to the Control Module.
Do not connect the 9000783 USB cable to PC computer until the rapidCAST Interface
software is installed and the system is powered up. See Connecting the Winch to a PC for
details.
The Processor connector on the Control Module is not used for normal operation. Keep the
dust cap installed.
Figure 14. rapidCAST Cable Connections (Large Vessels)
rapidCAST User’s Guide March 2018
EAR-Controlled Technology Subject to Restrictions Contained on the Cover Page.
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Figure 15. rapidCAST Cable Connections (Small Vessels)
March 2018 rapidCAST User’s Guide
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EAR-Controlled Technology Subject to Restrictions Contained on the Cover Page.
Antenna Position
The rapidCAST system includes two types of antenna. The size of the vessel will determine which antenna
to use.
Omni Antenna – Use this antenna when the distance between the Interface Module and Control Module is less than 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 antenna at the probe).
Figure 16. Omni Antenna
Patch Antenna – Use this antenna when the distance between the Interface Module and Control Module is over 10 meters. See Figure 14 for cable connections.
Orientate the antenna as shown in Figure 17. The best reception is when the probe is in the center of the
approximately 30 degree cone.
Figure 17. Patch Antenna
rapidCAST User’s Guide March 2018
EAR-Controlled Technology Subject to Restrictions Contained on the Cover Page.
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Switch Functions
Emergency Stop – Removes all power except the 24 VDC Auxiliary power to maintain lights. There are
two emergency stop buttons; one on the Control Module and one on the Interface Module. If the emergency stop button is pushed in, turn and pull out to restore power. The rapidCAST system will reboot in a
few seconds.
Main Power – Turn switch off to remove all power to the system.
Brake – Removes the 24 VDC power to the winch break motor. Processor – Removes the 24 VDC to the
Control Module processor.
Motor Driver – Removes the 48 VDC to the motor controllers.
Control Switch – The switch changes control between the PC running the rapidCAST Interface Software
(PC Control position) and the joystick (Local Control position). When 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 off.
Joystick – If the toggle switch is in the Local Control position, use the joystick to manually operate the
winch. OUT will deploy cable; IN will retract cable. The winch is limited to 100 RPM maximum while using the joystick.
When the joystick is not actively being used, the toggle switch should be set to PC Control to
properly engage the brake.
Figure 18. Control Module Figure 19. Interface Module
The control panel is equipped with a joystick that allows the spool to be controlled directly by
an operator on deck. Local control is convenient when the user needs to operate the spool
without having to coordinate with a person running the PC. The joystick is typically used
when retrieving the probe out of the water and bringing it on deck, or when putting the
probe back into the water. The joystick is sensitive and should be operated slowly!
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