Installation Manual

Installation Manual
Gill Instruments
Ultrasonic Wind Sensor with Heating
Kongsberg Maritime Part no.s:
700506 (Wind Sensor incl. Junction Box)
47753629 (Wind Display – 230V)
700095 (Wind Display – 115V)
309332 (Optional Junction Box)

This manual describes the installation of the

Ultrasonic Wind Sensor w/Junction Box and 2 m
cable of Gill Instruments and the Wind Display
(optional) of Observator Instruments.

Wind Sensor w/Cable Wind Display (optional)

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Document revisions
Written by Checked by Approved by

Rev Date Sign Date Sign Date Sign

A 06.08.00 HHO 06.08.00 VS 06.08.00 TMF
B 27.08.01 HHO 28.08.01 VS 28.08.01 TMF
C 18.08.05 CBM 19.08.05 TH 19.08.05 TH
D 20.02.07 HHO 22.02.07 SG 22.02.07 TH
E 13.04.07 SEM 14.04.07 AKT 24.04.07 TH
F
G
H
The original signatures are recorded on the company’s logistic data system.

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Table of Contents

1 INTRODUCTION ............................................................................................................. 5

2 SPECIFICATIONS ............................................................................................................ 6

3 INSTALLATION ............................................................................................................... 9
3.1 General information................................................................................................... 9
3.2 Location of the units................................................................................................... 9
3.2.1 Ultrasonic Wind Sensor..................................................................................... 9
3.2.2 Junction Box ........................................................................................................ 9
3.2.3 Wind Display (optional).................................................................................... 9
3.3 Logistics ....................................................................................................................... 9
3.4 Handling.................................................................................................................... 10
3.5 Mechanical installation............................................................................................ 10
3.5.1 Ultrasonic Wind Sensor................................................................................... 10
3.5.2 Junction Box ...................................................................................................... 10
3.5.3 Wind Display (optional).................................................................................. 11
3.6 Electrical installation................................................................................................ 11
3.6.1 Ultrasonic Wind Sensor w/Junction Box...................................................... 11
3.6.2 Wind Display (optional).................................................................................. 13

4 INSTALLATION DRAWINGS .................................................................................... 14

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Document history

Rev. Reason for issue

A Initial issue.
B Height of Junction Box corrected in section 2 and in Figure 5.
C Corrections made to the equipments mounting orientation. Figure 1: Wind
Observer Mounting Orientation” deleted from document
D Optional Junction Box info added. Steps 3) and 6) in section 3.6 added.
Figure 1 updated. Old Figure 5 deleted. New Figure 6 inserted.
E Added KM drawing number 311368.
F
G
H

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1 INTRODUCTION
This document describes the installation of Gill Instruments
Wind Measuring System.
The Gill Instruments Wind Measuring System is fast responding
and accurate system designed for measuring wind speed and direction
on board ships where high demands to the liability of equipment is
required.
The Wind Measuring System consists of two components, an
outdoor Ultrasonic Wind Sensor (including Junction Box) from Gill
Instruments for measuring wind speed and direction and an indoor
Wind Display from Observator Instruments for indication of wind
speed and direction.
The instrument is provided with a data output for serial transfer of
measuring values to the DP-system.

Note ! Unless otherwise noted, the Wind Display is not part of a standard
delivery, and must be ordered especially.

This document contains the specifications, procedures and

drawings necessary for the installation of both the indoor and
the outdoor unit.

WARNING ! The equipment includes high voltages (220V).

Note ! The guidelines for installation presented here must be regarded as a

base for detailed plans prepared by the installation shipyard. These
plans must include drawings, instructions and procedures specific to
the ship in which the equipment is to be installed. These drawings
must be approved by the local maritime classification society.

Unless otherwise noted, all installation work described in this

document is to be performed by yard/customer personnel.
It is the yard/customer responsibility to assure that their installation
personnel are sufficiently qualified, and that proper caution is taken to
avoid injuries on or damage of life / health / environment / equipment
/ property.

Kongsberg Maritime AS accepts no responsibility for any

damage or injury to the system, ship or personnel caused by
drawings, instructions or procedures not prepared by
Kongsberg Maritime.

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2 SPECIFICATIONS
Mechanical specifications
Ultrasonic Wind Sensor:
Height: .................................................................................... 405 mm
Width (diameter): .................................................................. 210 mm
Weight:........................................................................................ 1.5 kg
Junction Box
Height (incl. PG-glands):................................................... 120.4 mm
Width: ..................................................................................... 130 mm
Depth (excl. PG-gland): .......................................................... 80 mm
Weight:........................................................................................< 3 kg
Optional Junction Box
Heigh....................................................................................... 180 mm
Width: ..................................................................................... 255 mm
Depth (excl. PG-gland): ........................................................ 102 mm
Weight:...................................................................................... 0.85 kg
Wind display (optional):
Height: .................................................................................... 144 mm
Width: ..................................................................................... 144 mm
Depth:........................................................................................ 94 mm
Weight:........................................................................................ 0.8 kg
Maximum thickness:................................................................. 8 mm

Electrical specifications
Ultrasonic Wind Sensor:
Voltage input (measuring part):................................... 9 to 30 VDC
Power consumption (measuring part): ..............40 mA at 12 VDC
Voltage input (heating part - optional): ............... 24 VDC or VDC
Power consumption (heating part - optional):........................... 3A
Measurement output: ................................................... 1, 4 or 10 Hz
Communication: ................................................... RS422 or 4-20 mA
Baud Rate: ...........................1200, 2400, 4800, 9600, 19200 or 38400

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Data Format: ............................. 8 data bits, odd, even or no parity

Batteries: ......................................................................................None
Wind display (optional):
Voltage input (normal): .............................................. 115/230 VAC
Voltage input (optional): .......................................................24 VDC
Power consumption: ........................................................max. 20VA
Input signal: .......................... Current Loop w/ASCII information
Input signal (optional) ......................... Pulse, Potmeter and RS422
Output signal: .................................................................Daisy Chain
Output signal (optional):......... 4 – 20 mA, RS232 and NMEA-183
Batteries: ......................................................................................None

Environmental specification
Ultrasonic Wind Sensor:
External Construction:.........................................Stainless Steel 316
Enclosure protection: ..............................................IP66 (NEMA4X)
Operating Temperature:................................................. -55 to 70 °C
Sonic Temperature: ......................................................... -40 to 70 °C
Operating Range (wind speed): .......... 0 to 65 m/s (0 to 145 mph)
Operating Range (wind direction):.................................... 0 to 359°
Accuracy (wind speed):................................................................. 2%
Accuracy (wind direction): .......................................................... +2°
Resolution (wind speed): ....................................................0.01 m/s
Resolution (wind direction): ...........................................................1°
Humidity: ......................................................................5 to 100 %RH
Precipitation: .................................................................... 300 mm/hr
EMC:..................................BS EN 50081-1:1992 (Emissions class B)
........................................................ BS EN 50082-2:1992 (Immunity)
........................................................................................... FCC class A
Icing:................................MILSTD810E Method 521.1 Procedure 1

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Junction Box:
External Construction:.................................................... ABS Plastic
Colour: ................................................................................. RAL 7035
Gasket: ............................................................................... Polyuretan
Enclosure protection: ...................................................................IP67
Operating Temperature:................................................. -40 to 80 °C
Flame Resistant:..................................................................UL-94-HB
Humidity: ......................................................................0 to 100 %RH
Optional Junction Box:
External Construction:.................................................... ABS Plastic
Colour: ................................................................................. RAL 7035
Gasket: ............................................................................... Polyuretan
Enclosure protection: ...................................................................IP66
Operating Temperature:................................................. -40 to 80 °C
Flame Resistant:....................................................................UL94-5V
Humidity: ......................................................................0 to 100 %RH
Wind display (optional):
Operating Temperature:................................................. -30 to 60 °C
Enclosure protection: ...................................................................IP40
Humidity: ........................................................................5 to 90 %RH
EMC:................................................EN 50081-1 class B, EN 50082-2

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3 INSTALLATION

3.1 General information

This chapter presents the procedures and drawings for
installation of both the outdoor Ultrasonic Wind Sensor (incl. the
Junction Box) and the indoor Wind Display

3.2 Location of the units

3.2.1 Ultrasonic Wind Sensor
The ultrasonic wind sensor must be placed far from any object,
which may influence the measuring result. The best result is
reached by placing the wind sensor at the top of the ship’s
mast.
Installation of the sensor immediately above the ship’s deck is
unfavourable, especially if the deck consists of side faces over
which the wind is forced. In this case there may be turbulence
of wind speed and wind direction, which has no coherence
with the undisturbed wind speed and direction.

3.2.2 Junction Box

The Junction Box is mounted within 2 metres from the
Ultrasonic Wind Sensor (refer to Figure 4)

3.2.3 Wind Display (optional)

The wind display should be located in the central control room,
or elsewhere where needed.
The Wind Display is provided with a data output for serial transfer of
measuring values to other locations.

3.3 Logistics
Safety: General safety precautions should
be followed when working with
the Ultrasonic Wind Sensor and
the Wind Display.
Personnel qualifications: Trained mechanical worker.
Min. no. of personnel: One
Ship location: No recommendations.

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Special tools required: None

3.4 Handling
Handle both the Ultrasonic Wind Sensor and the Wind Display
with care. They are both delicate instruments.

3.5 Mechanical installation

3.5.1 Ultrasonic Wind Sensor
For mechanical installation of the Ultrasonic Wind Sensor
proceed as follows:

Note ! The Wind Sensor must be mounted vertically.

1) To meet stiffness requirements, assure that the dimension

of the bracket for mounting of the Anemometer, is
minimum 3/16” (refer to Figure 1).
2) Mount the yard/customer supplied mounting bracket to
fit the selected plane on a pole or similar as shown in
Figure 1.
3) Mount the Anemometer to the mounting bracket as
shown in Figure 2.

Note ! Assure that the “North indicating line on label” of the Anemometer
(refer to Figure 3) is pointing preferably within +2º referred to the
vessel bow.

4) Use Panduit straps or equivalent, and fasten the cable

running from the Anemometer to Junction Box.

3.5.2 Junction Box

For mechanical installation of the Junction Box proceed as
follows:
1) Decide where to mount the Junction Box. Note that it
must be mounted within 2.0 metres from the
Anemometer. Refer to Figure 4 and to Figure 5 for
Standard Junction Box, and to Figure 4 and to Figure 6 for
the Optional Junction Box
2) Drill four holes at the mounting place according to Figure
5 (Standard Junction Box) and to Figure 6 (Optional
Junction Box).

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3) Use four screws, washers and nuts and fasten the

Junction Box to the mounting plate/wall/etc.

3.5.3 Wind Display (optional)

For mechanical installation of the Wind Display proceed as
follows:
1) Cut Out in panel according to Figure 7.
2) Insert the wind display into the cutout, and fasten it with
the delivered fastening devices.

3.6 Electrical installation

For electrical installation, refer to KM drawing number 311368.

3.6.1 Ultrasonic Wind Sensor w/Junction Box

The Ultrasonic Wind Sensor comes with a flying 9 pair cable
ready terminated in the Junction Box.
The glanding in the Junction Box has equal to or greater ingress
protection than the anemometer. All cores of the cable are
terminated individually and no cores are joined together.
Joining cores together could damage the unit permanently. The
screens of each pair are joined together inside the anemometer
therefore these should be joined and taken to chassis as close as
possible to the cable termination.
If the cable is likely to be exposed to mechanical damage, then it
must be routed in a suitable conduit or cable tray.
The electrical installation of the Ultrasonic Wind Sensor is
executed as follows:
1) At delivery, check that all used cores of the cable from the
Anemometer are terminate in the Junction Box (refer to
Table 1).
2) At delivery, check that all spare cores of the cable from
the Anemometer are terminated one-by-one with shrink
tubes. All single shrink tubes are thereafter collected in
one bigger shrink tube.

Note ! Inside the Cover of the Junction Box there is a sticker showing the
terminations described in Table 1.

3) Terminate the cable running from the Junction Box to the

Wind Display in the Junction Box in a 1:1 manner, with
respect to signals of the Anemometer cable terminals.
Refer to Table 1.

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4) Avoid long grounding loops.

Do not common the “Supply -VE“, “Heater –“ or
“Analogue 0 Volt” to the screens or chassis ground, this
could damage the unit permanently
5) Spare cores are terminated one-by-one with shrink tubes.
All single shrink tubes is thereafter collected in one bigger
shrink tube.
6) Connect the Earth Strap as shown in Figure 1.

Terminal Signal Name Remarks

block no.
X1-1 Supply +VE Standard
X1-2 Supply -VE Standard
X1-3 Heater + Standard
X1-4 Heater - Standard
X1-5 RS422 TX+ Standard
X1-6 RS422 TX- Standard
X1-7 RS422 RX+ Standard
X1-8 RS422 RX- Standard
X1-9 Protective Earth / Screen Standard
- Analogue Ch.1 voltage output Optional
- Analogue Ch.1 current output Optional
- Analogue Ch.2 voltage output Optional
- Analogue Ch.2 current output Optional
- Analogue Ch.3 voltage output Optional
- Analogue Ch.3 current output Optional
- Analogue 0V reference/current return Optional
- Analogue 0V reference Optional

Table 1 Ultrasonic Wind Sensor Cable Termination at the Junction

Box

Note ! The Heater unit itself is optional, but the heater cable terminations in
the Junction Box are standard.

Note ! The analogue connections are mainly used when retrofitting wind
measurement systems connected to old DP-systems requiring
analogue input signals from the wind sensors.
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3.6.2 Wind Display (optional)

For electrical installation of the Wind Display proceed as
follows:
1) Terminate the cable from the Junction Box in the Wind
Display termination rack as shown in Figure 8.
2) If the Wind Display is daisy chained, terminate the
conductors of the daisy chain cable in the Wind Display.
Refer to Figure 8.

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4 INSTALLATION DRAWINGS
The following drawings / documents are enclosed:

Title Dwg./Doc Rev. Sheets

No.
Mounting Bracket Arrangement Details Figure 1 N/A 1
Anemometer Mounting Arrangement Figure 2 N/A 1
Wind Observer Mounting Alignment Figure 3 N/A 1
Anemometer Cable Arrangements Figure 4 N/A 1
Standard Junction Box Dimensions and hole taking Figure 5 N/A 1
Optional Junction Box Dimensions and hole taking Figure 6 N/A 1
Wind Display Cutout Dimensions Figure 7 N/A 1
Wind Display Signal Termination Figure 8 N/A 1
Gill Anemometer Indicator Connection Diagram 311368 B 1

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Figure 1: Mounting Bracket Arrangement Details and Earth Strap Details

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w/washer

Figure 2: Anemometer Mounting Arrangement

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Figure 3: Wind Observer Mounting Alignment

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2.0 metres cable

Junction Box

Figure 4: Anemometer Cable Arrangements

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130
113,5 80

120,4
63,5

Front view Side view

Figure 5: Standard Junction Box Dimensions and hole taking

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M32
M20

M20
M32

Figure 6: Optional Junction Box Dimensions and hole taking

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Figure 7: Wind Display Cutout Dimensions

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Figure 8: Wind Display Signal Termination

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