KH1207

SHIP'S TECHNI TECHNICAL CAL MANUAL MANUAL INSTALLATION, COMMISSIONING and MAINTENANCE INFORMATION for Mk V TRANSCEIVERS (CAE-A30-20 & CAE-A30-21)

PUBLI PUB LICA CATION TION KH1207 Issue Is sue 3

February 2009

Kelvin Hughes Limited Kelvin Lim ited  New North Road, Hainault, Ilford, Il ford, Essex IG6 2UR, UK  Tele phone: +44 20 8502 6887 Facsim Fac simile: ile: +44 20 8559 8526 Telex: 896401 www.kelvinhughes.com

Registered Office: New North Road, Hainault, Ilford, Essex IG6 2UR Incorporated in England No. 1030135 VAT No: GB 918080917/000

CONFORMITY CON FORMITY STATEMENT STATE MENT This equipment has been designed to comply with IMO regulations and IEC standards.

COPYRIGHT COPY RIGHT  Copyright Kelvin Hughes Ltd. 2009

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, translated or stored in any form or by any means, without the written  permission of Kelvin Hughes Limited. Technical details contained in this publication are subject to change without notice.

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CONFORMITY CON FORMITY STATEMENT STATE MENT This equipment has been designed to comply with IMO regulations and IEC standards.

COPYRIGHT COPY RIGHT  Copyright Kelvin Hughes Ltd. 2009

All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, translated or stored in any form or by any means, without the written  permission of Kelvin Hughes Limited. Technical details contained in this publication are subject to change without notice.

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AMENDMENT AMEND MENT RECORD RECORD When an amendment is incorporated into this publication, the details should be recorded  below. Where the equipment has been modified, the modification number number shown on the Amendment Instruction Sheet is also to be recorded. Amdt. No.

Isssue 3 Is

Date Inserted

Initials

Mod. No.

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CONTENTS PRELIMINARY PAGES

Title Page Amendment Record Page iii Contents (this page) v Foreword vii Health and Safety Notice Page ix Emergency Resuscitation xi Electrostatic Caution Page xii Code of Safe Working Practices CP 225 Equipment Registration CHAPTERS

Chapter 1 - General Description Chapter 2 - Specification Chapter 3 - Technical Description Chapter 4 - Installation Chapter 5 - Commissioning Chapter 6 - Maintenance Chapter 7 - Parts List Annex A - Long Cable Runs and Inline Power Supply Annex B - Sector Muting Installation and Servicing Reports

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FOREWORD This Ship's Manual provides installation, commissioning and maintenance information for the MkV X-Band Upmast Transceivers and Antennas. Installation and maintenance must only be undertaken by qualified service engineers or by Kelvin Hughes and their approved agents. Unauthorised repair of equipment during the Warranty period will invalidate the Warranty. If you wish to undertake the maintenance of the equipment, then you need to ensure that the service engineers have undertaken a training course approved by Kelvin Hughes.

A general description of the equipment and the specification is given in Chapters 1 and 2 respectively. A full technical description to unit level is given in Chapter 3, including block  diagrams and interconnection diagrams. The Installation Information in Chapter 4 includes all physical installation information, including waveguide installation, and generic cabling data. For detailed cabling information to the display, refer to your System Manual. The Commissioning Information in Chapter 5 includes generic information on commissioning from the master display and information specific to this equipment. For  detailed information on commissioning from the display, refer to your System Manual. The Maintenance Information in Chapter 6 covers routine maintenance procedures, fault diagnosis and repair to unit level. A Parts List to unit level is provided in Chapter 7. A section is provided at the end of the manual for inclusion of customer information relating to the specific equipment supplied to your ship, including installation and service reports, and software information. When operating, installing or maintaining your system, this manual should be used in conjunction with the following: System Manuals provided for your particular installation, which provide Operating and System Installation and Commissioning Information. Manuals for the other equipment supplied as part of the System. Refer overleaf for contact details for the Kelvin Hughes Customer Service Group.

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Page vii

If a unit exhibits a fault, and you are unable to fix it, and therefore require a service engineer  to attend your vessel, please contact our Service Control Centre, giving full details of the following: 1. 2. 3. 4. 5. 6. 7.

Name of vessel (Phone or Fax number if fitted) Equipment type Software status (version number) (if applicable) Next port of call, ETA/ETD and ship's agents Fault description (with as much detail as possible) Purchase order number with invoicing details Contact Name

You may contact our direct line, send a fax or send an email. Kelvin Hughes, Customer Services Group, New North Road, Hainault, Essex IG6 2UR  (UK) Phone: Main UK Switchboard: 44 (0)20 8502 6887 Direct Service Line & Out of Hours Emergency Technical Support: 44 (0)20 498 1761 email: service@kelvin hughes.co.uk 

If you have any technical queries or require any technical information regarding your Kelvin Hughes bridge equipment you may phone our direct Service Line. You may also contact our  direct line, send or fax an email to: [email protected] 

If you require information on our training facilities or would like to have a quote for training,  please give as much detail as possible. You may contact our direct line, send a fax or send an email to: [email protected] 

For quotation of spares, or if you require any information regarding availability, lead times etc, you may contact our direct line, send a fax or send an email to: [email protected] 

Please Note. All quote requests must have full contact details. Our preferred method of  contact is email, but Fax or Post may be used. We normally supply the quotation by email. For more information regarding our contract services or to arrange a meeting with a member  of our team you may email us at the following address. Those customers already holding an agreement with us may also use this email address to request a service, providing the same information as mentioned for service (no purchase order number required). You may contact our direct line, send a fax or send an email to: [email protected] 

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IMPORTANT NOTICES HEALTH AND SAFETY 1

All personnel are required to study these notices and familiarise themselves with all ap plica ble safety precautions and bring them to the attention of others in the vicinity. HIGH VOLTAGE WARNING

CD-0845

LETHAL HIGH VOLTAGES ARE PRESENT IN THE TRANSCEIVER 

2

A current of 100 mA passing through the human body for one sec ond can kill. This can occur at voltages as low as 35 V AC or 50 V DC. Some equipment in the sys tem uses electrical power that can be lethal. Whenever practical, before carrying out installation, maintenance or re pair, personnel involved must: (1)

Isolate the equipment from the electrical sup ply.

(2)

Make tests to verify that the isolation is com plete.

(3)

Ensure that power cannot be accidentally reconnected.

DO NOT OPEN ANY OF THE UNITS WHEN THE RADAR IS OPERATIONAL UNLESS FULLY QUALIFIED TO DO SO.

3

If it is essential to work on the equipment with power connected, work must only be undertaken by qualified personnel who are fully aware of the danger involved and who have taken adequate safety precautions to avoid contact with dangerous voltages. HEALTH HAZARD

CD-0844

4

This equipment contains materials which produce toxic fumes when ignited.

5

The inhalation of dust and fumes or any contact with lu bricants when cleaning the equipment may be tem porarily harmful to health, de pending on individual allergic reactions. Com ponents which are broken or overheated may release toxic fumes or dust and must be treated with caution. Do not inhale the fumes and ensure that the dust and debris do not enter open cuts or abra sions. It is prudent to regard all damaged com ponents as being potentially toxic, requiring careful handling and ap pro priate dis posal.

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RADIATION HAZARD: NON-IONISING AERIAL RADIATION HAZARD: INJURY CAN RESULT FROM EXPOSURE TO THE MAIN BEAM OF A STATIONARY RADAR AERIAL. DO NOT STAND LESS THAN 2m FROM THE CENTRAL FRONT FACE OF THE AERIAL.

6

It is accepted in most countries that no significant hazard is presented by radio frequency mean power density levels up to 10mW/cm. RF power levels in excess of this may cause harmful effects, particularly to the eyes. 7

Users of cardiac pacemakers should be aware that radio frequency transmissions, can damage some such devices or cause irregularities in their operation. Persons using a  pacemaker should ascertain whether their device is likely to be affected before ex posing themselves to the risk of malfunction. SAFETY ALOFT AERIAL ROTATION: BEFORE MAINTENANCE TO THE TURNING MECHANISM TAKES PLACE, DISABLE AERIAL ROTATION.

8

When working aloft, en sure that it is brought to the attention of someone in authority at deck or at ground level and that suit ably placed warning notices are posted warning that work aloft is in progress. Ensure that the means of access aloft is secure and beware of wet or  slip pery ladder rungs and working areas. 9

When working on or near a radar scan ner and other moving or RF radiating equipment, ensure that it is switched off and that the fuses have been removed and retained. PERSONAL PROTECTION

10

Personal protection must be used whenever the possibility of an uncontrolled hazard exists. For exam ple, a suitable face visor, gloves and a body apron should be worn when handling cathode ray tubes, as a precaution against in jury in the event of breakage. EQUIPMENT SAFETY

11

Do not run the radar with the rotating joint output disconnected.

12

Removal of printed circuit boards with power connected can damage FETs and Integrated Circuits.

13

The circuitry used on the equipment PCBs utilises CMOS Integrated Circuits. All the relevant CMOS precautions must be taken to a void damage to CMOS circuitry when any  board is removed. 14

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The equipment should be serviced by qualified agents only.

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ELECTRIC SHOCK RESUSCITATION 1

SHOUT FOR HELP. SWITCH OFF ELECTRICITY IF POSSIBLE. SWITCH OFF ELECTRICITY IMMEDIATELY. IF NOT POSSIBLE, DON'T WASTE TIME SEARCHING FOR A SWITCH

2

REMOVE CASUALTY FROM DANGER.

3

REMOVE ANY OBVIOUS OBSTRUCTION TO BREATHING.

SAFEGUARD YOURSELF WHEN REMOVING CASUALTY FROM HAZARD. IF CASUALTY IS STILL IN CONTACT WITH ELECTRICITY AND THE SUPPLY CANNOT BE ISOLATED, STAND ON A DRY NON-CONDUCTING MATERIAL (RUBBER MAT, WOOD, LINOLEUM). USE RUBBER GLOVES, DRY CLOTHING WOODEN BROOM, STOOL, CHAIR, LENGTH OF DRY ROPE OR WOOD TO PULL OR PUSH CASUALTY AWAY FROM THE HAZARD.

IF CASUALTY IS NOT BREATHING, START RESUSCITATION AT ONCE. GET HELP.

SHOUT & SHAKE CASUALTY (FOR RESPONSE) LOOSEN NECKWARE, TILT HEAD BACKWARDS & PUSH CHIN UPWARDS

CHECK FOR SIGNS OF CIRCULATION, SIGNS OF LIFE (< 10 SECONDS).

SIGNS OF LIFE/CIRCULATION PRESENT

SIGNS OF LIFE/CIRCULATION ABSENT

HEART HAS STOPPED BEATING, LAY CASUALTY ON THEIR BACK ON FIRM SURFACE eg. FLOOR PERFORM CPR: HEEL OF HAND IN CENTRE OF BREASTBONE WITH OTHER HAND ON TOP (FINGERS OFF CHEST) WRISTS & ELBOWS LOCKED COMPRESS DOWN 5cm. REPEAT 30 TIMES IN TOTAL (SPEED 100 PER MINUTE)

OPEN AIRWAY, PINCH THE NOSE & HOLD THE CHIN. WHEN NORMAL BREATHING COMMENCES, PLACE CASUALTY IN RECOVERY POSITION

KEEP CASUALTY AT REST. MOVE USING A STRETCHER. WATCH CLOSELY, PARTICULARLY FOR DIFFICULTY IN BREATHING. LIGHTLY COVER WITH BLANKETS OR OTHER MATERIALS

CD-1265

TAKE NORMAL BREATH, SEAL MOUTH, BLOW STEADILY (WATCHING CHEST RISE). REMOVE MOUTH, CHECK THAT CHEST FALLS, REPEAT RESCUE BREATH.

CONTINUE CPR WITH 30 CHEST COMPRESSIONS, THEN 2 BREATHS UNTIL CASUALTY REVIVES & COLOUR IMPROVES, OR HELP ARRIVES OR YOU ARE EXHAUSTED.

ISSUE 2

MEDICAL ASSISTANCE MAY BE OBTAINED ON / AT ...............................................

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ATTENTION OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES

CAUTION Handling of Electrostatic-Sensitive Semiconductor Devices Certain semiconductor devices used in the equipment are liable to damage due to static voltage. Observe the following precautions when handling these devices in their  unterminated state, or sub-units containing these devices: (1) Persons removing sub-units from an equipment using these devices must be earthed by a wrist strap and a resistor at the point provided on the equipment. (2) Soldering irons used during the repair operations must be low voltage types with earthed tips and isolated from the mains voltage by a double insulated transformer. (3)

Outer clothing worn must be unable to generate static charges.

(4) Printed Circuit Boards (PCBs) fitted with these devices must be stored and transported in anti-static bags. CD-1100

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CP 225 CODE OF SAFE WORKING PRACTICES FOR THE INSTALLATION AND COMMISSIONING OF KELVIN HUGHES LIMITED MANUFACTURED EQUIPMENT

This code must be followed when installing or commissioning any Kelvin Hughes Limited product. Failure to follow this code invalidates the equipment warranty.

SAFETY

Reference must be made to the Safety Warnings located at the beginning of each Kelvin Hughes Limited Manual and must be read and understood. These include but are not limited to, the knowledge and understanding of: ‘Electric Shock Resuscitation’, the safety interlock system, all lethal voltages present, source of supply to all equipment, any hazardous material in the equipment or area of work, radiation hazard from the beam of a Radar Antenna and any antenna rotation hazard.

Before working on antennas the following conditions must be met: •

A responsible person (such as the officer of the watch) must be informed that there will be an engineer working on the system.

•

The system interlock must be activated.

•

The source of power to the system must be isolated.

•

•

•

Warning notices must be posted at the system power source and at all displays showing ‘MAN WORKING ALOFT DO NOT SWITCH ON’. Local language considerations must be taken into account and included with the English statement above. When working above a height of 1.5 metres safety harnesses must be worn and must be clipped in to the superstructure. All tools must be securely lashed to ensure that they can not present a drop hazard.

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1

CP 225 INSPECTION

Before commencing work, the proposed installation locations must be inspected and accepted as being suitable for the equipment to be mounted securely following the installation procedures which can be found in the relevant Kelvin Hughes Limited manual under ‘installations’. All characteristics of the equipment must be taken into account when inspecting the proposed location such as weight and torque of turning mechanisms, regulation height of Radar display units and type, length and specification of cables or waveguide. All equipment must be inspected and checked off against the indent on unpacking, if  practicable, for completeness and damage. Any discrepancies against the indent or damage to equipment must be reported to Kelvin Hughes Limited as soon as possible  but in any case within 24 hours.

TECHNICAL CONSIDERATIONS Earthing: Earthing is to be completed by following the appropriate installation instructions, ensuring that all screws and bolts are tightened sufficiently and that any cable or braid is routed correctly. Cabling: Cables are to be of correct specification and rating and are to be run in suitable cable trays or guides. Any bulkhead penetrations, which are opened, must be closed thus maintaining existing fire proofing precautions. Metal cable ties must be used when running cable in any deckhead or bulkhead areas. Cables are to be terminated as per current IEEE regulations thus ensuring correct practices are followed. Siting and Mounting of Equipment: The equipment must be mounted following the relevant Kelvin Hughes Limited installation manual. Particular attention must be paid to the tightening of bolts and the use of ‘Nylon’ locking nuts in areas of vibration such as on antennas and turning mechanisms. Stainless steel nuts, washers and bolts must be used for all outdoor installations. No modifications are to be made to any Kelvin Hughes Limited equipment unless previously authorised in writing by Kelvin Hughes Limited and a copy of such authorisation kept with the equipment manual(s). Maintenance and Care of Equipment: Kelvin Hughes Ltd recommends inspection on a three monthly basis of all equipment. Particular attention is to be paid to turning mechanisms and scanners, which must be kept clean using only a soft cloth and soap and water - No chemical agents or corrosive cleaning agents are to be used . Any excessive end-to-end play, or excessive noise in scanners should be reported to Kelvin Hughes Limited within 24 hours of discovery.

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2

KH1207 Chapter 1

CHAPTER 1

GENERAL DESCRIPTION CONTENTS

Paragraph

1 7 10

Page

INTRODUCTION SYSTEM DESCRIPTION Functional Description

1.3 1.4 1.4

ILLUSTRATIONS

Figure

1 2

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Page

System Block Diagram X-Band Upmast Configuration with CAN Bus Interface

1.6 1.7

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KH1207 Chapter 1

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KH1207 Chapter 1

CHAPTER 1

GENERAL DESCRIPTION INTRODUCTION

1

The MkV X-Band Transceiver is available in a 10 kW upmast configuration only, where the transceiver electronics are co-located with the turning mechanism. The following versions of MkV upmast transceiver are available:

2

3

4

5

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(1)

Low Speed Antenna rotation - 24 rpm (CAE-A30-20). This configuration is used for normal applications.

(2)

High Speed Antenna rotation - 40 rpm (CAE-A30-21). This configuration is used for high speed craft.

The following antennas can be used: (1)

1.3 m X-band Low Profile Antenna (LPA-A13)

(2)

1.9 m X-band Low Profile Antenna (LPA-A19)

(3)

2.5 m X-band Low Profile Antenna (LPA-A25)

The transceiver can be interfaced to the display system as follows: (1)

Parallel interface, where the display is connected directly to the transceiver.

(2)

CAN bus interface, where the parallel data to and from the transceiver is converted to CAN bus format for the display system by a Transmitter Interface Unit (TIU), which consists of the power unit and a CANbus to Parallel adapter   board.

The transceiver obtains its DC supplies from external sources, which are typically as follows, depending on system configuration: (1)

Systems using a parallel data interface derive most power supplies from the display. For the CAE-A30-20, the 24 rpm system, the +26V for the motor is derived from the display. For CAE-A30-21, the 40 rpm system, an additional 40V Power Supply, CZZ-A22, is required to provide the supply to the motor. For  details of the 40V Power Supply, refer to the relevant system manual.

(2)

Systems using a CAN bus interface derive all power supplies from the Transmitter Interface Unit (TIU) associated with the MkV Transceiver. Note that the TIU powers both 24 rpm and 40 rpm motors, so the 40V Power Supply is not required for this configuration. For details of the TIU refer to the relevant system manual.

Figures 1 and 2 shows the system configuration for the transceiver.

Page 1.3

KH1207 Chapter 1 SYSTEM DESCRIPTION

6

7

The MkV Transceiver (CAE-A30-20 and CAE-A30-21) comprises the following main units: (1)

Terminals PCB (CTX-A368)

(2)

Modulator (CTX-A332)

(3)

Magnetron/RF Head

(4)

Receiver (CTX-A356)

(5)

Azimuth PCB (CAE-A402/3)

(6)

Tx Monitor (optional) (CTX-A198)

A cast cover fitted with a rain seal is secured in position by four captive screws.

8

An ON/OFF switch is located by the cable entries on the outside of the case and switches off the control signal to the antenna motor, preventing the antenna from rotating, and  prevents the magnetron from radiating RF. This is achieved as follows: (1)

One pole of the switch is connected in the RUN line from the display. When switched OFF the Magnetron cannot radiate as the Run line is broken at the switch.

(2)

The second pole of the switch is connected in the Motor Start line from the display. When switched OFF the Antenna Motor cannot run.

The Safety Switch must be set to OFF before removing the cover. Functional Description

9

Figure 1 provides a block diagram of the transceiver.

10

The transceiver uses +27 V, -12 V and the magnetron heater supply from the display or  TIU to power the transceiver circuits and either +26 V for the low speed antenna motor  from the display or TIU, or +40 V for the high speed antenna motor from the 40V Power Supply or TIU, depending on the installation. 11

The Terminals PCB feeds the incoming power and data from the display to the other  assemblies, providing modulator trigger pulses, pulse selection gating, antenna switching, voltage regulation and a tune voltage. The PCB also receives video from the Receiver  and feeds the video signals to the display system. 12

The Modulator provides a high voltage pulsed supply via a pulse width circuit and FET circuit into a pulse transformer to drive the magnetron. The magnetron can be set to radiate on one of four pulse lengths (Short, Medium, Long and Very Long), selected from the display, and controlled by the Modulator. The Modulator only generates RF if the Run command is present from the display and the transceiver is not muted. The transmitter PRF is normally set to Jitter mode.

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KH1207 Chapter 1 13

The RF Head contains the Magnetron, Circulator, Pulse Limiter and Low Noise Front End (LNFE). The Low Noise Front End comprises an RF Amplifier, Local Oscillator  and IF Head Amplifier. 14

The magnetron generates 10 kW pulses which are fed to the circulator and rotating joint onto the antenna. The small leakage of power across the circulator is fed into the pulse limiter and is used by the LNFE as a tune signal. 15

Return signals from the antenna are fed through the rotating joint and circulator to the limiter and the LNFE, where they are amplified, mixed and converted to IF levels to interface with the receiver main IF. 16

The Receiver amplifies and filters the IF from the RF Head and then feeds the signal to a cascade logarithmic amplifier which produces video for the display system. The logarithmic amplifier is fitted with AFC circuits. 17

Sector muting of the transceiver is controlled from the display. A local sector mute control board can be fitted as an option.

18

The Heading Line and Azimuth Data are produced by the interaction between an opto-interrupter disc and sensors located on the Azimuth PCB.

19

Provision is made to monitor the transmitted RF signal from the antenna via a Tx Monitor Arm, located under the antenna, and to monitor the received RF signal via the Rx Monitor Cavity located in the RF Head. This allows the performance of the transmitted and received signals to be monitored, and any degradation in performance to be detected. 20

The transceiver provides one SYNC and one VIDEO coaxial output.

21

The two versions of transceiver use the following motor drives to rotate the antenna:

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(1)

Low Speed (CAE-A30-20) employs a 24 V DC motor and rotates the antenna at 24 rpm. This motor is controlled by the Motor Start PCB (CTX-A359).

(2)

High Speed (CAE-A30-21) employs a 40 V brushless DC motor, and rotates the antenna at 40 rpm. This motor is controlled by the Brushless Motor PCB (CAE-A236).

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KH1207 Chapter 1

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    E     )       C      T     Y     A     S      S      A     F     A     U      L     R     6      B     P     S      E     6      M     N     I     T     A     N     A     D     D     N     I     R  -     W     C      O      E     R       N     T     I     R     N     O       E     N     D     E     E     U     T     T     D     H     C      Q      E     T     I     E     W     I     N     A     R     M     U      T     D     F     R     S      A       E     N     C       E       S     A     O     U      T     L     I     R     (       N     T     E     C      A     F     R     E     T     N     I     L     E     L     L     A     R     A     P     T     E     I     C      Y     N     A     A     U      F     L     R     P     H       E     S       C     T     T     I     D     I     N     I     W     L     M     S      E     O      R     L     R     E     L     /     F     T     A     O       I     N     R     T     A     R     P     O 

    E     C      A     F     R     E     T     N     I     S      U      B     N     A     C      T     E     I     N     C      Y     U      A     A     F     L     H     R     P     C      S       E     I     I     T     T     D     N     I     M     W     S      S      O      R     U      R     E     B     F     /      T     N     O      N     A     T     I     C      R     O 

    S      E     I     L     P     P     U      S      R     O      T     O      M     V     0      4    +     )      D     T     T     E     S      O      2     A     E     N     2     M     P     U      A  -     S      I     Z     N     H     T     D     Z     W     G      N     E     L     C      O      I     E     L     U      D     H     H     A     S      D     R     W     T       P     E     O      S     N     F     R     I     V     T     O      0      A     D     4     C      E     T     O      S      O      L     (      U      M

    T     U      P     N     I     S      N     I     A     M     1     E     U      S      S      I       4       0        1       7          D       C 

Figure 1 - System Block Diagram

Page 1.6

Issue 3

KH1207 Chapter Chap ter 1

Figure 2 - X-Band Upmast Configuration with CAN Bus Interface

Isssue 3 Is

Page 1.7

KH1207 Chapter Chap ter 1

THIS PAGE INTENTIONALLY BLANK 

Page 1.8

Issue 3

KH1207 Chapter Chap ter 2

CHAPTER 2

SPECIFICATION CONTENTS CON TENTS

Paragraph

1

Isssue 3 Is

Page

TECH NI  NICAL CAL SPECI SPECIFI FICA CAT TIONS Freq Fre quency RF Pulse Length and PRF Sync Out put  put Recceiver Re Oper Op erat ating ing Tem per  peraature and Humidity Turning Turn ing Mecha Mechanism Data In put Power Require Requirement ment (Includ (Including ing Motor Motor Sup ply)

2.3 2.3 2.3 2.3 2.4 2.4 2.4 2.4

Page 2.1

KH1207 Chapter 2

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Page 2.2

Issue 3

KH1207 Chapter 2

CHAPTER 2

SPECIFICATION TECHNICAL SPECIFICATIONS

1

Technical specifications for MkV Transceivers are provided below. All quoted values are nominal.

Frequency

X (I) Band

9410 30MHz

Peak Power Output

10kW

Magnetron Life

10,000Hrs (Typically)

RF Pulse Length and PRF

PULSE LENGTH

PULSE WIDTH (nominal)

PRF (nominal)

SHORT (S)

55 ns

3000 pps

MEDIUM (M)

210 ns

1500 pps

LONG (L)

610 ns

750 pps

VERY LONG (VL)

610 ns

375 pps

Sync Output

1 x 75, not less than +12V amplitude. Pulse to Pulse Jitter

This will normally be activated and gives a maximum of 15 s from the nominal period. This function can  be inhibited.

An RS232 link is available for test purposes.

Issue 3

Page 2.3

KH1207 Chapter 2 Receiver

Type

Logarithmic Receiver  

Log-law

Nominal 50 mV/dB (20 dB/V)

RF input dynamic range

0 dBm to -90 dBm typical

IF

60 MHz

Video output

1 x 75 

Peak video output level

0.5 V to +5.0 V nominal

System overall noise figure

7.0 dB max

Operating Temperature and Humidity

Ambient Temperature Range Humidity

-25C to +70C 95% at +40C

Turning Mechanism Data

Azimuth Data Heading Data

90 pulses per revolution, +20 V amplitude nominal 1 pulse per revolution +20 V amplitude nominal

Input Power Requirement (Including Motor Supply)

24 RPM system 40 RPM system

Page 2.4

170 W, 220 VA 230 W, 330 VA

Issue 3

KH1207 Chapter 3

CHAPTER 3

TECHNICAL DESCRIPTION CONTENTS Paragraph

1 10 10 12 24 26 26 29 30 34 35 38 39 40 41

Page

PHYSICAL DESCRIPTION FUNCTIONAL DESCRIPTION TRANSCEIVER TERMI NALS PCB (CTX-A368) TRANSMITTER CIRCUITS RF HEAD Signal Paths High Power Low Power RECEIVER CIRCUITS MOTOR DRIVE CIRCUITS AZIMUTH/HEADING LINE PCB (CAE-A402/3) TRANSMITTER MONITOR PCB (CTX-A198) SECTOR MUTE PCB (CTX-A162) TRANSCEIVER POWER SUPPLIES ANTENNA MOTOR POWER SUPPLIES

3.3 3.5 3.5 3.5 3.6 3.7 3.7 3.7 3.7 3.8 3.8 3.8 3.8 3.8 3.9

ILLUSTRATIONS Figure

1 2 3

Issue 3

Page

MkV Transceiver: Module Locations Transceiver (CAE-A30-20 and CAE-A30-21): Block Diagram Transceiver (CAE-A30-20 and CAE-A30-21): Interconnection Diagram

3.4 3.11/12 3.13/14

Page 3.1

KH1207 Chapter 3

THIS PAGE INTENTIONALLY BLANK 

Page 3.2

Issue 3

KH1207 Chapter 3

CHAPTER 3

TECHNICAL DESCRIPTION PHYSICAL DESCRIPTION

1

The Upmast Transceiver is available as 24 rpm or as 40 rpm versions, either of which may be fitted with 1.8m or 2.4m antennas. The 40 rpm version (CAE-A30-21) uses a  brushless DC motor. 2

Figure 1 shows the mechanical arrangement of the transceiver.

3

The MkV Transceiver (CAE-A30-20 and CAE-A30-21) comprises the following main units: (1)

(2)

4

Issue 3

An Electronics Unit, with the following mounted on it: (a)

Transceiver Terminals PCB (CTX-A368)

(b)

Modulator (CTX-A332)

(c)

Logarithmic Receiver (CTX-A356)

(d)

Azimuth/Heading Line PCB (CAE-A402/3)

(e)

Magnetron/RF Head

(f)

Transmitter Monitor PCB (CTX-A198)

The housing, with the following units mounted in it: (a)

Brushless Motor PCB (CAE-A236) (CAE-A30-21 only) or Motor Starter PCB (CTX-A359) (CAE-A30-20 only)

(b)

Antenna Motor 

(c)

Gearbox

(d)

RF Rotating Joint, with Optional Tx Monitor PCB

(e)

Mount for the antenna

A cast cover fitted with a rain seal is secured in position by four captive screws.

Page 3.3

KH1207 Chapter 3 5

An ON/OFF switch is located by the cable entries on the outside of the case and switches off the control signal to the antenna motor, preventing the antenna from rotating, and  preventing the magnetron from radiating RF. This is achieved as follows: (1)

One pole of the switch is connected in the RUN line from the display. When switched OFF the Magnetron cannot radiate as the Run line is broken at the switch.

(2)

The second pole of the switch is connected in the Motor Start line from the display. When switched OFF the Antenna Motor cannot run.

The Safety Switch must be set to OFF before removing the cover.

WARNING SWITCH OFF AT SAFETY SWITCH

Tx MONITOR ARM (OPTIONAL)

NOTE: WHEN REFITTING UNIT DO NOT DAMAGE MATING FACES OF WAVEGUIDE Rx MONITOR CAVITY CTX-A173 (OPTIONAL)

AZIMUTH PCB CAE-A402-3 AZIMUTH PCB LOCKING SCREW & CALIBRATION GUIDE

M4 CIRCULATOR RETAINING SCREWS (CAPTIVE) RECEIVER ASSEMBLY CTX-A364 (ON SIDE)

MOTOR STARTER PCB CTX-A359 or MOTOR DRIVE PCB CAE-A236 (AT BACK OF CASTING)

STATIC STUD

SAFETY SWITCH LOCATED ON UNDERSIDE OF CASTING TERMINALS PCB CTX-A368

DISCONNECT ELECTRICAL PLUGS MODULATOR PCB CTX-A332 & MAGNETRON CTX-A197 (BENEATH COVER)

M5 CHASSIS RETAINING BOLTS

TRANSCEIVER UNIT SHOWN WITH FRONT COVER REMOVED

Tx MONITOR PCB CTX-A198 (UNDERNEATH) ANTENNA MOTOR TERMINAL BLOCK TB2

CD-3737

ISSUE 2

Figure 1 - MkV Transceiver: Module Locations

Page 3.4

Issue 3

KH1207 Chapter 3 FUNCTIONAL DESCRIPTION (FIGURES 2 AND 3) TRANSCEIVER TERMINALS PCB (CTX-A368)

6

The Terminals PCB provides termination for all the Transceiver connections and routes all signals from the display to the transceiver and from the transceiver to the display as well as between the units within the transceiver. The Transceiver Terminals PCB feeds the incoming power supplies to the units within the transceiver, and derives the +15 V supplies for  use within the transceiver from the Modulator +27 V input. 7

It has the circuitry for receiver bandwidth control, antenna motor switching and dummy sync pulses for mute periods. A link in the antenna motor switching circuit allows the antenna to either rotate all the time power is present, or only when the transceiver is set to Run. Another link allows dummy sync pulses to be produced when the transceiver is muted, this is normally disabled and is only required for old series Kelvin Hughes displays. TRANSMITTER CIRCUITS

8

The transceiver uses a 10 kW magnetron to generate the RF output. The magnetron is driven by the Modulator (CTX-A332), which is associated with the MOS Driver PCB (CTX-A339). 9

The Modulator provides a high voltage pulse of selectable width, via a FET driver circuit and pulse transformer, to drive the magnetron.

10

The Modulator provides the following:

11

12

Issue 3

(1)

Low voltage supply (+14 V, +5 V, -7 V) generation from the +27 V input.

(2)

+350 V power supply generation from the +27 V input. This supply used to  provide the pulses to the magnetron.

(3)

Driver circuits for the pulse transformer.

(4)

Sync pulse circuit.

(5)

Microprocessor control of the transmitter, including the control and protection circuits. On-board low voltage power supply monitoring and temperature sensing are associated with the microprocessor, but the data is not output from the transceiver. A diagnostic port is provided for maintenance purposes, and this allows this data to be accessed.

The following inputs are applied to the FET modulator: (1)

Pulse Length, Run and Mute from the display.

(2)

External Trigger (not used in this application).

The following signals are output from the FET modulator: (1)

Tx Ready to the display.

(2)

Sync Pulse to the display.

(3)

Magnetron Drive pulse to the magnetron. Page 3.5

KH1207 Chapter 3 13

The modulator board requires the following power supplies from the Display: (1)

+27 V at 1.5 A.

(2)

+8.5 V at 550 mA (Magnetron Heater supply).

14

All other supplies are derived on the PCB from the +27 V supply. The modulator   produces a +13 V to +16 V supply, a +5 V supply, a -7 V supply and a +350 V HT supply. The +350 V HT is used to power the Pulse Transformer drive circuit. 15

The PCB is controlled from a microcontroller which receives control signals, trigger   pulses and internal modulator circuit trip signals and produces high voltage enable and  power output trigger pulses. The microcontroller generates the 50 second warm up time period for the magnetron heaters. The microcontroller also r eads the internally generated power supply voltages and the temperature of the PCB. The microcontroller does not indicate that a supply or  the temperature is within the test limits, this data is only available via a diagnostic port. The default values for the microcontroller are stored in an on-board EEPROM. A watchdog circuit resets the microcontroller when power is applied to the PCB, and resets the microcontroller if  activity on the bus stops for more than 2 seconds. LED D53 is lit when the microcontroller is operating normally, and extinguishes when the watchdog loop is interrupted, i ndicating that the microcontroller is not running. 16

The 10 kW magnetron requires a drive pulse of 5.8 kV at between 4 and 5 A. This is  produced by a pulse transformer from the +350 V supply. The Mod Trig pulses are  preprogrammed for pulse width and p.r.f. and are fed to the MOS Driver PCB. If the pulse transformer drive circuit runs at too high a frequency, the circuit trips and a restart is attempted. 17

The microcontroller sets the pulse width for the magnetron pulses, depending on the p.r.f.

18

The modulator can be triggered either from the internal trigger pulses or from external trigger pulses. The default uses the internal pulses, and automatically changes to the external trigger mode when external trigger pulses are applied. The external trigger pulses are not used in this application. 19

The PCB generates a 75 ohm sync pulse for the display.

RF HEAD

20

21

The RF Head comprises: (1)

A 10 kW Magnetron

(2)

RF Filter  

(3)

Ferrite Circulator  

(4)

PIN Diode Driver and Limiter 

(5)

Slotted filter shim

(6)

Low Noise Front End (LNFE)

The Low Noise Front End combines an RF amplifier, balanced mixer, electronically tuned local oscillator and IF head amplifier.

Page 3.6

Issue 3

KH1207 Chapter 3 Signal Paths High Power

22

Typical RF pulse conditions for the 10kW magnetron are: (1)

Short Pulse: 50 to 70 ns at 4.0 A

(2)

Medium Pulse: 200 to 260 ns at 4.5 to 5.5 A

(3)

Long Pulse: 580 to 650 ns at 4.5 to 5.5 A

(4)

Very Long Pulse: 580 to 650 ns at 4.5 to 5.5 A

23

The magnetron energy is fed into port 2 of the circulator, and due to the rotational  properties of the circulator, emerges at port 3 and is fed out to the rotating joint, and the antenna. 24

A small amount of the magnetron energy leaks across the ferrite junction and into the  pulse limiter. The limiter in turn limits this energy to a safe level for the low noise front end to use as a tune signal. The active PIN Limiter is triggered by the sync pulse. At this time the PIN is driven so that its attenuation is increased. A time constant in the circuit slopes the attenuation to a low level over a range of a couple of nautical miles. The circ uit gives improved detection of close range targets. Low Power

25

Signals which are target returns are received by the antenna and are fed to port 3 of the circulator, via the rotating joint. The signals e merge at port 1, and then are fed to the pulse limiter. Normally these signals are of low amplitude, and will not be limited by the pulse limiter. The limited signals are amplified by the LNFE and mixed at 60MHz, to produce IF for the receiver. RECEIVER CIRCUITS

26

The Logarithmic Receiver PCB (CTX-A356) is mounted in a screened case to avoid interference from high power RF signals within the transceiver.

27

The Logarithmic Receiver contains eight logarithmic amplifier stages plus associated filters and output drivers, which provide three video outputs.

28

A tuneable narrow band filter, located between the 5th and 6th logarithmic amplifiers, is switched into circuit by the Long Pulse and Very Long Pulse selector. A video detector  and three independent video outputs are provided. When the Performance Monitor is switched ON, a signal representing the power output from the Antenna is injected into the output stage of  the Receiver to give a Power Monitor Plume on the display. 29

Issue 3

The Logarithmic Receiver provides power and AFC tuning control for the LNFE with a tune indication signal to the Terminals PCB.

Page 3.7

KH1207 Chapter 3 MOTOR DRIVE CIRCUITS

30

The turning motor is driven by DC supplies from the Transceiver power supply as follows: (1)

The low speed version (CAE-A30-20) uses a conventional 24 V DC motor with  brushes, which is driven directly from a +26 V DC supply. The motor starting torque is controlled by the +26 V Motor Starter PCB (CTX-A359) which  provides a soft start facility. This is provided by means of a controlled current  being applied to the motor on power up for a period of 0.5 seconds. The motor  then has full power available from the power unit. LK1 on this PCB is made for  CAE-A30-20.

(2)

The high speed version (CAE-A30-21) uses a brushless motor which is provided with a +36/40 V DC supply. The motor is driven by the Brushless Motor PCB (CAE-A236), which provides switching of the 40 V supply to control the start up characteristic and the speed of the motor so maintaining a near constant rotational speed for the antenna.

AZIMUTH/HEADING LINE PCB (CAE-A402/3)

31

The Turning Mechanism generates the Azimuth and Heading Line using a slotted optical disc with sensors, which is located on the final drive. A single heading line pulse and 90 azimuth pulses are produced for each rotation of the antenna. 32

The Azimuth/Heading Line PCB (CAE-A402/3) is mounted so that the slotted disc rotates within the opto-coupler slots on the PCB. The azimuth and heading line pulses for  the display are produced by an interaction between the opto-interruptor disc and sensors located on the PCB. 33

The Azimuth/Heading Line PCB position can be adjusted on the casting. Loosening the mounting screws allows the assembly to be moved positive or negative six degrees for  fine heading line adjustment. The slotted disc can be rotat ed if the fine adjustment is not enough. TRANSMITTER MONITOR PCB (CTX-A198)

34

The Transmitter Monitor PCB produces +180 V to drive the neon detector mounted at the end of the Monitor Arm and the circuitry to process the resulting signal.

SECTOR MUTE PCB (CTX-A162)

35

The optional Sector Mute PCB allows the selection of Sector Muting in 4 degree steps when there are 90 azimuth pulses per antenna revolution.

TRANSCEIVER POWER SUPPLIES

36

The Transceiver receives its power from the Display, an Inline Power Unit or a TIU. Prior to working on the transceiver the power must be isolated at the appropriate unit. Switching OFF the safety switch mounted on the transceiver case will stop transmission and rotation.

Page 3.8

Issue 3

KH1207 Chapter 3 ANTENNA MO TOR POWER SUPPLIES

37

The +26 V DC supply for the low speed motor is supplied from the Display, an Inline Power Unit or a TIU, set to +26 V. The 36/40V for the high speed motor is supplied from a 40 V Power Supply (CZZ-A22) for a single, parallel controlled system or a TIU set to +36 V for  a CANbus system.

Issue 3

Page 3.9

KH1207 Chapter 3

THIS PAGE INTENTIONALLY BLANK 

Page 3.10

Issue 3

KH1207 Chapter 3 X-BANDANTENNA LAP-A13, LPA-A19, LPA-A25

+36V/40V    1    L    P

   2    B    T

DC SUPPLY TO ANTENNA MOTOR

   3    L    P

BRUSHLESS MOTOR DRIVER CAE-A236

   2    L    P    5    L    P

MONITOR ARM PART OF CAE-A198 (OPTIONAL)

HIGH SPEED MOTOR

Tx MON NEON

HIGH SPEED MOTOR CAE-A30-21 GEARBOX ROTATING JOINT

+26V

FILTER

AZ/HL PCB CAE-A406-3 LOCATION 5

   A    L    P

LOW SPEED MOTOR

PLA

SAFETY SWITCH START

+26V MOTOR STARTER CTX-A359

RUN

   B    L    P

LOW SPEED MOTOR CAE-A30-20    M    L    P

Rx MONITOR CAVITY CTX-A173 LOCATION 8 (OPTION)

   L FLYING LEAD    L    P    N    L    P

   A    L    P

Tx MON PCB CTX-A198 LOCATION 7 (OPTION)

DC SUPPLIES MOD SYNC Tx READY

TERMINALS PCB CTX-A368 LOCATION 2

   E    L    P TRIGGER MUTE RUN LP/MP LPRE PULSE    H    L    P

   H    L    P

10kW MODULATOR CTX-A332 LOCATION 4 Gn    B    L P

HIGH VOLTAGE POWER SUPPLY UNIT

400V

MAGNETRON DRIVER

MOD TRIG

MOSFET DRIVER PCB CTX-A339

Y BRAID

MAGNETRON CTX-A197

FET DRIVE    A    L    P

CONTROL CIRCUITS D53 RUNNING

LOW PASS FILTER 45-750-0015-001

SECTOR MUTE PCB CTX-A162 LOCATION 6

CIRCULATOR 45-646-604

   1 PIN DIODE DRIVE    L AND LIMITER    P CTX-A512

FILTER SHIM NTX-1194

LOGARITHMIC RECEIVER CTX-A364/CTX-A356 LOCATION 3

+5V & TUNE

60MHz IF

38 CORE MULTICORE FROM DISPLAY INTERSWITCH UNIT or TIU

CD-6920

Figure 2

Issue 3

MAG HEATER MUTE -12V/-15V RUN Tx READY TUNE CONT. MP/LP TUNE LED HEADING LINE

   G    L    P

   D    L    P

Rx TRIG TUNE PULSE LENGTH TUNE IND +15V

   E    L    P    A    K    S

   A    K    S    B    K    S    C    K    S

LOW NOISE FRONT END (LNFE) CTX-A515

LOG AMP CONTROL CIRCUITS    C    L    P

PULSE WIDTH

BANDPASS FILTER

LOG AMP

VIDEO SYNC

   F    L    P

MOD +27V AZIMUTH Rx MON

   K    L    P

Tx MON PULSE    C VIDEO OUTPUT (COAX)    L    P

   D    L    P

OUTPUT CIRCUITS

TRANSCEIVER CAE-A30-20, CAE-A30-21

   A AZIMUTH/HEADING LINE    L    P

ISSUE 2

Transceiver (CAE-A30-20 and CAE-A30-21): Block Diagram

Figure 2

Page 3.11/12

KH1207 Chapter 3 AZ/HL PCB CAE-A402/3

TERMINALS PCB CTX-A368 (PART OF) LOCATION 2

FILTER

0V HL AZ +27V AZ TEST AZ TEST

MOTOR

TB2 1 2 3 4 5 6 7 8

+26V

SAFETY SWITCH

+26V MOTOR STARTER PCB CTX-A359

PLA 0V

1 2 3

1 2

SKM

MOD +27V MOD 0V N/C MAG HTR +8V MAG HTR 0V

SAFETY SWITCH TB2 1 2 3 4 5 6 7 8

PL1 +40V +40V 0V 0V

1 2 3 4

BRUSHLESS MOTOR DRIVER PCB CAE-A236

+40V +40V 0V 0V

RUN+ RUN-

1 2 3 4 5 6

SKM 1 2 3 4

PL5 2 1

RUN (V) RUN (SW) AE STARTER AE 0V

RPM/10 +40V SHUTDOWN IND OVERTEMP BOARD GND +5V SOURCE

L1 1 L2 2 L3 3

LOCATION 4

4PLB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5 2

MOD +27V 0V (Rx SYNC)

4 1 3

MAG HTR +8V Tx READY Rx SYNC

4PLA 1 4 5 10 8 9 3 7 6 2

MOTOR FLY-LEAD

BRUSHLESS MOTOR UNIT

PL2

1 +5V 2 PS3 3 PS2 4 5 6 (NOT EARTH) 0V PLANE 7 PS1 8

0V (SIG) RUN Tx READY MP LP SYNC (SCRN) Rx SYNC 0V SECTOR MUTE

PL3

PL4

MODULATOR CTX-A332 2PLE

LOW SPEED MOTOR CONNECTIONS CAE-A30-20

PART OF 38 CORE TO DISPLAY OR INTERSWITCH UNIT

4 SOLDER PIN 3 2 1 5 6

1 2 3 4 5 6

1 +27V MOD 2 +27V SW 3 4

PLB

+27V MOTOR START +26V MOTOR START 0V +26V SWITCHED RETURN

LOCATION 5

2PLA

MOTOR FLY-LEAD

2PLL

MAG HTR 0V 0V (SIG) RUN MP LP SYNC (SCRN) EXT TRIG PRE PULSE SECTOR MUTE

Y GN

MAGNETRON CTX-A197 (10KW)

Rx MONITOR CAVITY CTX-A173 (OPTION)

+27V 1 Rx MON 2

CIRCULATOR

LOCATION 8

 PIN DIODE DRIVER & LIMITER CTX-A512

HIGH SPEED MOTOR CONNECTIONS CAE-A30-21

PL1 2PLK

2 CORE Tx MON ARM

PART OF 38 CORE TO DISPLAY OR INTERSWITCH UNIT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

MOD +27V MOD 0V MOD +27V MOD +27V MOD 0V MOD 0V +12V/15V N/C AZ N/C N/C NEON (0V) NEON Rx MON

2PLG 1 2 3 4 5 6 7 8 9 10 11 12

MAG HTR +8V MAG HTR 0V MUTE -12V/15V 0V (SIG) RUN Tx READY TUNE CONT TUNE LED MP LP HL

1 2 3 4

2PLD -12V Rx SYNC LP SP +15V +27V Tx MON PULSE 0V TUNE LED 0V (SIG)

5 14 1 6 3 4 7 2 10 13

TUNE CONT 12

INHIBIT 0V Rx TRIG +15V

 RECEIVER CTX-A356 LOCATION 3

3PLC 5 14 1 6 3 4 7 2 10 13 8 9 11 12

SECTOR MUTE PCB CTX-A162 LOCATION 6

+15V 0V HL AZ SECTOR MUTE

CD-6551

Figure 3

Issue 3

6SKH 1 2 3 4 5 6

SCREEN SYNC VIDEO SCREEN

VIDEO 2 0V VIDEO 1 0V VIDEO 3 0V

2PLC VIDEO SCR VIDEO OUT

1 2 3

2PLN 2PLH 1 2 3 4 5 6

1 2 3 4 3SKA

 LNFE CTX-A515 SKB 1 0V 2 VCO TUNE SKA +5V SKC IF

3PLB 2 1 3PLD

2PLF 1 2 3 4

3PLE

-12V 0V Rx SYNC VCO TUNE LP SP +15V +27V Tx MON PULSE 0V TUNE LED 0V (SIG) NOISE SW IND IND 1 NOISE MONITOR MON OUT

+15V 0V -12V +15V N/C 0V MON ON (-12V) HL NEON AZ NEON (0V) SECTOR MODE Tx MON PULSE

1 2 3 4 5 6 7 8

1 2 3 4 5 6

 Tx MONITOR PCB CTX-A198 7PLA 1 2 3 4 5 6 7 8

LOCATION 7

+15V 0V -12V N/C MON ON (-12V) NEON NEON (0V) Tx MON PULSE

ISSUE 2

Transceiver (CAE-A30-20 and CAE-A30-21): Interconnection Diagram

Figure 3

Page 3.13/14

KH1207 Chapter 3 AZ/HL PCB CAE-A402/3

TERMINALS PCB CTX-A368 (PART OF) LOCATION 2

FILTER

0V HL AZ +27V AZ TEST AZ TEST

MOTOR

TB2 1 2 3 4 5 6 7 8

+26V

SAFETY SWITCH

+26V MOTOR STARTER PCB CTX-A359

PLA 0V

1 2 3

SKM

1 2

MOD +27V MOD 0V N/C MAG HTR +8V MAG HTR 0V

SAFETY SWITCH TB2 1 2 3 4 5 6 7 8

PL1 +40V +40V 0V 0V

1 2 3 4

BRUSHLESS MOTOR DRIVER PCB CAE-A236

+40V +40V 0V 0V

RUN+ RUN-

1 2 3 4 5 6

SKM 1 2 3 4

PL5 2 1

RUN (V) RUN (SW) AE STARTER AE 0V

RPM/10 +40V SHUTDOWN IND OVERTEMP BOARD GND +5V SOURCE

L1 1 L2 2 L3 3

+5V PS3 PS2

(NOT EARTH) 0V PLANE PS1

LOCATION 4

4PLB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

5 2

MOD +27V 0V (Rx SYNC)

4 1 3

MAG HTR +8V Tx READY Rx SYNC

4PLA 1 4 5 10 8 9 3 7 6 2

MOTOR FLY-LEAD

BRUSHLESS MOTOR UNIT

PL2 1 2 3 4 5 6 7 8

0V (SIG) RUN Tx READY MP LP SYNC (SCRN) Rx SYNC 0V SECTOR MUTE

PL3

PL4

MODULATOR CTX-A332 2PLE

LOW SPEED MOTOR CONNECTIONS CAE-A30-20

PART OF 38 CORE TO DISPLAY OR INTERSWITCH UNIT

4 SOLDER PIN 3 2 1 5 6

1 2 3 4 5 6

1 +27V MOD 2 +27V SW 3 4

PLB

+27V MOTOR START +26V MOTOR START 0V +26V SWITCHED RETURN

LOCATION 5

2PLA

MOTOR FLY-LEAD

2PLL

MAG HTR 0V 0V (SIG) RUN MP LP SYNC (SCRN) EXT TRIG PRE PULSE SECTOR MUTE

Y GN

MAGNETRON CTX-A197 (10KW)

Rx MONITOR CAVITY CTX-A173 (OPTION)

+27V 1 Rx MON 2

CIRCULATOR

LOCATION 8

 PIN DIODE DRIVER & LIMITER CTX-A512

HIGH SPEED MOTOR CONNECTIONS CAE-A30-21

PL1 2PLK

2 CORE Tx MON ARM

PART OF 38 CORE TO DISPLAY OR INTERSWITCH UNIT

1 2 3 4 5 6 7 8 9 10 11 12 13 14

MOD +27V MOD 0V MOD +27V MOD +27V MOD 0V MOD 0V +12V/15V N/C AZ N/C N/C NEON (0V) NEON Rx MON

2PLG 1 2 3 4 5 6 7 8 9 10 11 12

MAG HTR +8V MAG HTR 0V MUTE -12V/15V 0V (SIG) RUN Tx READY TUNE CONT TUNE LED MP LP HL

1 2 3 4

2PLD -12V Rx SYNC LP SP +15V +27V Tx MON PULSE 0V TUNE LED 0V (SIG)

5 14 1 6 3 4 7 2 10 13

TUNE CONT 12

INHIBIT 0V Rx TRIG +15V

 RECEIVER CTX-A356 LOCATION 3

3PLC 5 14 1 6 3 4 7 2 10 13 8 9 11 12

-12V 0V Rx SYNC VCO TUNE LP SP +15V +27V Tx MON PULSE 0V TUNE LED 0V (SIG) NOISE SW IND IND 1 NOISE MONITOR MON OUT

SECTOR MUTE PCB CTX-A162 LOCATION 6

+15V 0V HL AZ SECTOR MUTE

CD-6551

Figure 3

Issue 3

6SKH 1 2 3 4 5 6

SCREEN SYNC VIDEO SCREEN

VIDEO 2 0V VIDEO 1 0V VIDEO 3 0V

2PLC VIDEO SCR VIDEO OUT

1 2 3

2PLN 2PLH 1 2 3 4 5 6

1 2 3 4 3SKA

 LNFE CTX-A515 SKB 1 0V 2 VCO TUNE SKA +5V SKC IF

3PLB 2 1 3PLD

2PLF 1 2 3 4

3PLE

+15V 0V -12V +15V N/C 0V MON ON (-12V) HL NEON AZ NEON (0V) SECTOR MODE Tx MON PULSE

1 2 3 4 5 6 7 8

1 2 3 4 5 6

 Tx MONITOR PCB CTX-A198 7PLA 1 2 3 4 5 6 7 8

LOCATION 7

+15V 0V -12V N/C MON ON (-12V) NEON NEON (0V) Tx MON PULSE

ISSUE 2

Transceiver (CAE-A30-20 and CAE-A30-21): Interconnection Diagram

Figure 3

Page 3.13/14

KH1207 Chapter 4

CHAPTER 4

INSTALLATION CONTENTS Paragraph

1 4 5 7 15 15 20 21 21 22 24 26 27 28 28 30 31

GENERAL COMPASS SAFE DISTANCES TRANSCEIVERS SAFETY NOTES EQUIPMENT LOCATION TRANSCEIVER/TURNING MECHA NISM OPTIONAL MAINS ISOLATOR (80-261-600) INSTALLATION TRANSCEIVER AND TURNING MECHA NISM Fitting the Transceiver/Turning Mechanism to the Ship Fitting the Low Profile Antenna Fitting the Monitor Arm OPTIONAL MAINS ISOLATOR (80-261-600) ELECTRICAL CON NECTIONS CABLE SPECIFICATIONS 38-Core Custom Built Ca ble 12-Core Com posite Cable

Page

4.3 4.3 4.3 4.4 4.5 4.5 4.6 4.6 4.6 4.7 4.8 4.8 4.14 4.15 4.15 4.15 4.15

KH1207 Chapter 4

CHAPTER 4

INSTALLATION CONTENTS Paragraph

1 4 5 7 15 15 20 21 21 22 24 26 27 28 28 30 31 32 33 35 36 37 44 45

Page

GENERAL COMPASS SAFE DISTANCES TRANSCEIVERS SAFETY NOTES EQUIPMENT LOCATION TRANSCEIVER/TURNING MECHA NISM OPTIONAL MAINS ISOLATOR (80-261-600) INSTALLATION TRANSCEIVER AND TURNING MECHA NISM Fitting the Transceiver/Turning Mechanism to the Ship Fitting the Low Profile Antenna Fitting the Monitor Arm OPTIONAL MAINS ISOLATOR (80-261-600) ELECTRICAL CON NECTIONS CABLE SPECIFICATIONS 38-Core Custom Built Ca ble 12-Core Com posite Cable 14 Core Com posite Ca ble Small Multi-Core Cables Power Ca bles 2-Core (Power): Co-axial Ca ble Co-axial Cable 75 ohms low loss (for extended cable runs) TRANSCEIVER PCB Locations and Cableform Routing Checks after Fitting

4.3 4.3 4.3 4.4 4.5 4.5 4.6 4.6 4.6 4.7 4.8 4.8 4.14 4.15 4.15 4.15 4.15 4.17 4.18 4.18 4.18 4.19 4.19 4.20 4.21 4.21

TABLES Table

1 2 3

Issue 3

Page

CABLE SPECIFICATION 38-CORE CABLE COLOUR ABBREVIATIONS 14-CORE CABLE COLOUR ABBREVIATIONS

4.15 4.16 4.17

Page 4.1

KH1207 Chapter 4 CONTENTS (continued) LIST OF ILLUSTRATIONS Figure

1 2 3 3 4 5 6 7

Page

Transceiver Fixing Centres and Outline Dimensions Transceiver Mast Mounting Assembling Antenna to Turning Mechanism (Sheet 1) Assembling Antenna to Turning Mechanism (Sheet 2) Suggested Antenna Lifting Arrangement Optional Mains Isolator: Installation Dimensions 38-Core Composite Cable: Installation Transceiver Connection Diagram

Page 4.2

4.9 4.10 4.11 4.12 4.13 4.14 4.23/24 4.25

Issue 3

KH1207 Chapter 4

CHAPTER 4

INSTALLATION GENERAL

1

This section provides installation information for MkV Upmast X-Band Transceivers.

2

Kelvin Hughes, or appointed agents, contracts only to supply the equipment, supervise the installation and final connection of the equipment. It is recommended that the installation is made by a fully qualified Kelvin Hughes Radar Engineer. 3

Forward planning for positioning the various units of the radar must be made before any installation work is carried out. A full survey is required in order to establish the ship's fitment. This can be arranged with the Technical Department of Kelvin Hughes or one of the approved agencies. Details of Agencies worldwide can be found in Publication KH401. COMPASS SAFE DISTANCES

4

Compass safe distances are stated on labels on all units and are as follows: Grade I (0.25 degree)

MkV Transceiver Transmitter Interface Unit

3.0 m 0.2 m

Grade II (1 degree)

1.8 m 0.1 m

TRANSCEIVERS

5

There are two versions of the MkV Upmast Transceiver covered in this publication, and the mounting instructions are the same for both the units: (1)

Low Speed Transceiver/Turning Mechanism CAE-A30-20.

(2)

High Speed Transceiver/Turning Mechanism CAE-A30-21.

6

The Low Speed (24 rpm) Transceiver/Turning Mechanism is used for normal applications. The High Speed (40 rpm) Transceiver/Turning Mechanism is used for high speed craft.

Issue 3

Page 4.3

KH1207 Chapter 4 SAFETY NOTES

Observe the Health and Safety Notices at the front of this manual. In particular the procedures given in the Kelvin Hughes document Code of  Safe Working Practices CP225 MUST be followed. 7

Electrical power supplies are to be isolated to any part of the platform when mounting an antenna/transceiver. A suitable safety platform or harness should be used to avoid  personal injury when working aloft. 8

Electrical supplies in the vicinity of the transceiver are to be isolated during installation.

9

A working platform is to be provided for installing or servicing the assembly. This should  be positioned approximately a metre below the base of the Transceiver housing with a guard rail surrounding it. 10

A flat steel plate (12mm thick approx.), pre-drilled (in accordance with Figure 1) is require to accommodate the Transceiver unit and the cable from the Display. The steel  plate must be mounted horizontally and braced with struts for rigidity. 11

The plate has to be sited in a clear area where the turning Antenna cannot be obstructed by any cables, mast halyards etc.

12

The Transceiver Unit must be hoisted to the fixing position using a secured block and tackle or rope strops.

13

Safety personnel must ensure that persons do not encroach on the area of work.

14

The Antenna and Transceiver Unit MUST NOT be lifted by the array, but secured and hoisted evenly.

Page 4.4

Issue 3

KH1207 Chapter 4 EQUIPMENT LOCATION TRANSCEIVER/TURNING MECHANISM

15

The Transceiver/Turning Mechanism is to be mounted on a rigid platform, which is  positioned so that the rotating antenna is clear of other structures and rigging to allow it to rotate. The height and position of the platform is to be such that the radiated beam is unobstructed forward (i.e. through the ship’s head) and the vertical radiated beam clearing the ship’s bow. 16

T he pr i ma r y c o ns i de r at i on mu s t b e t h e s t re n gt h of th e s u pp or t f o r t h e Transceiver/Antenna assembly. Details of this requirement are described in Figures 1 and 2. Other considerations are: (1)

The antenna must be mounted more than 3ft (914mm) above any flat surface greater than the diameter swept by the antenna. It must not be positioned in close  proximity of any magnetic compass or D/F aerial etc.

(2)

Masts, sampsons, posts and rigging of more than 0.6m (2ft) diameter can cause  blind sectors. Increasing the distance between the antenna unit and these objects will reduce the blind sectors that inhibit a good radar picture. Funnels, crosstr ees and other large areas can reflect energy and give rise to spurious echo returns especially in close proximity to land. Positioning the antenna close t o funnels and exhaust gasses can adversely affect antenna performance.

(3)

The transceiver/turning mechanism must not be mounted where the temperature exceeds 70C.

(4)

Antennas must be kept clear of ships radio and communication aerials to avoid electrical RF interference that will cause reflections on the radar PPI display. The Transceiver/Turning Mechanism must be kept clear of ship’s flexible communication aerials to avoid damage to both.

 NOTE: A heavy duty earthing strap or cable must be taken from the transceiver/turning mechanism to the ship’s earth. 17

The Antenna is to be mounted onto the Transceiver/Gearbox using the ‘O’ ring and fixings supplied.

18

Where the total distance between the transceiver and the display is between 65 and 180 metres, the co-axial cables in the 14 Core or 38 Core cable ar e to be replaced by Low Loss Co-axial cables. 19

Where the distance is greater than 180 metres, the Low Loss cable must be used with the Head and Line Receiver Units. The Receiver shall be sited as close as possible to the display or interswitch unit. The Inline Power Supply (HRC-A28-1) provides the DC supplies to the Transceiver and contains the Line Head Amplifier (RAN-A26). If the Inline Power Supply is not required (when a TIU is used), the Line Head Amplifier (RAN-A26) is supplied as a se parate item. The Line Receiver (RAN-A27-2) is always a separate item. Details of installation using long cable runs is provided in Annex A.

Issue 3

Page 4.5

KH1207 Chapter 4 OPTIONAL MAINS ISOLATOR (80-261-600)

20

The Mains Isolator must be sited adjacent to the display or in the area of the operators control room and connected in series with the main display. INSTALLATION

TRANSCEIVER AND TURNING MECHANISM WARNING ENSURE THAT ALL POWER SUPPLIES IN THE VI CINITY OF THE TRANSCEIVER/TURNING MECHANISM ARE ISOLATED BEFORE ANY INSTALLATION TAKES PLACE. CAUTION Do not remove the transparent film covering the waveguide outlet as this prevents the ingress of water or moisture.

21

The Antenna and Transceiver are specified and supplied separately. Refer to Figure 1 in this chapter for outline dimensions and fixing centres. The following criteria are to be observed when installing: (1)

The transceiver/turning mechanism is fitted with a Low Profile Antenna.

(2)

For transceivers mounted in excess of 1.8 m above the deck, it is recommended that a service platform and guard rail are fitted.

(3)

Use a suitable jointing compound or sealant to prevent corrosion between the  platform and the transceiver. CAUTION The Antenna Window must not be painted

(4)

Page 4.6

Any chipped or damaged surfaces must be painted with polyurethane paint.

Issue 3

KH1207 Chapter 4 Fitting the Transceiver/Turning Mechanism to the Ship WARNING THE UNIT MUST NOT BE LIFTED BY MEANS OF THE SWING CASTING. THE LIFTING SUPPORTS MUST GO UNDER THE CASTING. IF IT IS NECESSARY TO FIT THE ANTENNA BEFORE INSTALLING THE TRANSCEIVER/TURNING MECHANISM, THE TRANSCEIVER/TURNING MECHANISM MUST NOT BE LIFTED BY THE ANTENNA. THE TRANSCEIVER/TURNING MECHANISM MUST BE HOISTED TO THE FIXING POSITION USING A SECURED BLOCK AND TACKLE, OR BY ROPE STROPS.

22

To install the transceiver/turning mechanism, proceed as follows: (1)

Hoist the Transceiver/Turning Mechanism to the mounting plate.

(2)

Mount the Transceiver/Turning Mechanism facing forward (removable cover  facing aft). Fit the retaining bolts and torque load to 75 kg/m (50 lb/ft) then gain access to the interior by removing the rear cover.

 NOTE: The outer casing of the Transceiver/Turning Mechanism must be bonded to the  ship’s superstructure using a copper earthing strap connected to the earthing  point shown in Figure 1. 23

Issue 3

The connecting cable from the Transceiver to the Display should be kept to a maximum of 65 metres. For cable runs exceeding 65 m, see details in Annex A.

Page 4.7

KH1207 Chapter 4 Fitting the Low Profile Antenna

24

It is recommended that lifting slings are used in an arrangement similar to those shown in Figure 4 to position the low profile antenna on the transceiver/turning mechanism. CAUTION

When unpacking the Antenna, ensure that the Waveguide is not kinked, crushed or bent. Support the Antenna near the ends when lifting it out of its packing and when fitting into position on the Turning Mechanism. Do Not handle the Antenna by the Waveguide input.

25

To install the antenna, proceed as follows (refer to Figure 3): CAUTION When rotating the Antenna do not apply excessive force.

Ensure the Waveguide, on the underside of the Antenna, is not crushed or damaged.

(1)

Remove the protective caps, tapes etc. Ensure the waveguide faces are clean and free from grease.

(2)

Loosely attach the antenna to the swing casting using the 4, M8 x 75 mm bolts, washers and nyloc nuts supplied in the fitting kit, LPA-A165. Apply Loctite to all screws.

(3)

Connect the waveguide on the antenna to the rotating joint on the turning mechanism using two O-rings, mylar window, nuts, washers and bolts supplied in the Fitting Kit, LPA-A165. The mylar window is fitted between the two O-rings.

(4)

Waterproof the waveguide joint by sealing with a layer of greased plastic compound such as Henleys compound or Denso-Tape.

(5)

Finally tighten fasteners holding swing casting to antenna to a torque of 29 Nm.

Fitting the Monitor Arm

26

Fit the Monitor Arm (if supplied) onto the side of the casing and secure the clamp with the four retaining screws. The monitor arm cable is passed through the smaller ca ble gland and clamped. The cable screen is to be earthed by the ferrules in the cable gland assembly.

Page 4.8

Issue 3

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     C      0      7    +    o       t      C      C      5      0      2  -     4    +    :     E     R     U      T     A    :     R     Y     E     T     P     I     D     M     I     E     M     T     U       G      H     N     E     I     T     V     A     I     R     T     A     E     L     P     E      O      R

 ,       S      T     L      O      B     6      M    x     6       G      N     I      S      U      R     E     V     I     E      C       S      N     A     R     T      O      T     Y     A     R     R     A     A     N     N     E     T     N     A     E  .     L     3      B     E     M     R     E     U       S      G      S      I      A     F     N     E     E     E     H      S .      T  ,      D     D     E     E     D     E     I     V     F      O     A     R      N     P     N      S      E     T     R     N     E     A     H      S      Y     N     I     A     A     W     R      G      N     D     R     I     A     R     N     A     ”     A     N      O     “      S      N     T     T     E     I     U      T     F     N     N  .     A     1

 .     D     E     D     I     V      O      R     P      S      R     E     H      S      A     W     D     N     A      S      T     U      N  ,       S      T     L      O      B     E      S      U   .     L     A     E      S       G      N     I     R     "      O     "      H     T     I     W     T     N     I      O      J       G      N     I     T     A     T      O      R      O      T     D     E     E     F     A     N     N     E     T     N     A     E     L     B     M     E      S       S      A  .     2

     O      T     T     A     T     V     U      7      O      2     D      S ,      +     H     E      C      I     L     D     T     I     R     A     N     R     N     A     W     A     R     N      S         C      E      O     T     I     T     Y      S     T     I      N     I     A     E     E     R     T     F      O        C      E     A     N     V     R      S      A     I     A     L     N     E     N     A     E      C      N     N     T      S      E     R     N     T     E     I     N     N     T     A     A     R     M     T     A     X     E     Y     E     F     F     E     N     H      O       A     T     H     H     T     E      C     R     T       O      I     F     W     E      S      B

 .      S      T     L      O      B     8      M     E     V     I     T     P     A      C      R     U       O      F     E     H     T      G      N     I     W     E     R      C       S      N     U      Y     B     D     E     N     I     A     T     B      O      R      O     I      R     E     T     N     I     R     E     V     I     E      C       S      N     A     R     T      S      E      S      H     E     T      C      O       C      T     A      S      R      S      E      O     I      C      R      C      E     A     T  .     N     I     4

 .     T     U      N     D     N     A     L      G      N     E     T     H      G     I      T      O      T     D     E     D     I     V      O      R     P     R     E     N     N     A     P      S      E      S      U   ,       S      D     N     A     L      G      E     L     B     A      C      E     H     T     F      O      R     A     E     R     E     H     T     H      G      U   .      O      N     R     E     H     T     T     H       E      G     L     I     B     T     R     A     E     Y      C      V     R     E      O      T     H     T     N     T      O      E      S      N     E      S      L     A      O      B     P     D     A  .      C      5 

    3      E     U       S       S     I        0        3       7       3    -        D       C 

Figure 1 - Transceiver Fixing Centres and Outline Dimensions

Issue 3

Page 4.9

KH1207 Chapter 4

FWD

COPPER EARTH STRAP TO SHIP’S GROUND (TO BE SUPPLIED BY SHIPYARD) NOMINALLY 20mm x 2mm

MOUNTING PLATE 12mm MINIMUM THICKNESS

450 290

45

STEEL TUBE WALL THICKNESS 12mm MINIMUM

   0    0    1    9    4    2

DIAMETER 150mm MINIMUM Ø14 mm

MOUNTING PLATE AND STIFFENING PIECES 15mm STEEL

NOTE: IT SHALL BE NOTED THAT AS KELVIN HUGHES CANNOT CONTROL THE HEIGHT OF THE MAST IT IS THE SHIP’S RESPONSIBI LITY TO DETERMINE THE ULTIMATE SIZE OF THE MAST ALL DIMENSIONS IN MILLIMETRES UNLESS OTHERWISE STATED

CD-3817

ISSUE 2

Figure 2 - Transceiver Mast Mounting

Page 4.10

Issue 3

KH1207 Chapter 4

Figure 3 - Assembling Antenna to Turning Mechanism (Sheet 1)

Issue 3

Page 4.11

KH1207 Chapter 4

Figure 3 - Assembling Antenna to Turning Mechanism (Sheet 2)

Page 4.12

Issue 3

KH1207 Chapter 4 CODE No DRAWING PRACTICE TO BS 308 DO NOT SCALE

LPA-1097

THIRD ANGLE PROJECTION

USED ON

SEE NOTE 2

   L   T    A    I    U   D    T   O   E    N    F   N   H   R    T    O   E   I    U    D   W   T    Y   I    F    E    R   N    S   R    A    I    O   I    E    D   C    T   E    I    S    R   B    T    B   S    A    U   A   P   S    S   D   D   U    E   R   M    A   T    I    T  .    H   I    D   A   T    T   E    4    L   R   O   M   0    S   T   T   O    0    E   E    H   2    H   B   D    E   W    G   O   S    O    U   T   O   T  .    D    H   I    S   L   D   E    T   T    N   T   C   L    I    S    I    V   I  .    I    M    L    I    D   S   L    E   Y    N   R   E    K   A    H   S    F   P   O   G   E    O   M   D   U   H    G    Y   O   E   H   U    T   C   S    N    I    H    R   D   U   V    E   E   R   L   N    P   T   O   E   I    O   I    D   K   V    L    M    F   E    R   I    P   L   E    C   O   K    E   I    C   U   T   C    H   L   D   N    T   B    O   E    S   U   R   S    I    P    P    N    T    E   O    N   S    E   R   C    E   I    E   S    M   R    T   B   U    U   S    C   U   T   O    I    O   V    O   D    D   N   N   E    I    Y   R    S    I    S   A   P    H   H    M    T   T   D   E    H    I    M   N   T    S   A

LPA-1052 SEE NOTE 3 IN 2 POS'NS

NOTES 1.ANTENNA WEIGHT = 70 Kg 2.ENSURE LIFTING STRAPS CAN NOT FREE RUN THRO' LIFTING HOOK.

DRAWN NRD

3.ENSURE THAT LIFTING STRAP CAN NOT  RUN FREE THRO' LIFTING STRAPS LPA-1052

TOLERANCESUNLESS OTHERWISE STATED

SCREWTHREADS

   3  .    S    S    I _    T    A    M    R    O    F _    3    A    /    A    E    D

COARSEPITCH INTERNAL EXTERNAL

BS3643 CLASS6H CLASS6g

HOLES

CLASSH13

MATERIAL

M/C

 ALL DIMENSIONS IN

MILLIMETRES (UNLESS OTHERWISE STATED)

TOBS4500 DIMENSIONAL TWODECIMALPLACES±0.15 ONEDECIMALPLACE ±0.5 NODECIMALPLACE ±1.0  ANGULAR ±1°

FINISH 1 ISS

DATE C/NOTE

SIG.

ISS

14-06-04

DR0458

NRD

DATE

C/NOTE

SIG.

TITLE

LPA RECOMMENDED LIFTING TECHNIQUE

SCALE

SIMILAR TO

NTS

CODE No.

LPA-1097 SHEET 1 OF 1

A3

Figure 4 - Suggested Antenna Lifting Arrangement

Issue 3

Page 4.13

KH1207 Chapter 4 OPTIONAL MAINS ISOLATOR (80-261-600)

27

With reference to Figure 5, secure the Mains Isolator in the required position (no fittings are sup plied).

   0   5    6   0    1   2

   0    3

80 160

120

WIRING FOR 3 PHASE

WIRING FOR SINGLE PHASE CABLE 211K 15mm 1.D CABLE GLAND

15mm 1.D CABLE GLAND

L1

L1

L2

L2

L3

L1

L3

L1

L2

L2

L3

L3

CONNECT SCREENS TO EARTH

FIT 20 AMP FUSES

15mm 1.D CABLE GLAND

FIT 20 AMP FUSES

15mm 1.D CABLE GLAND SHIP'S SUPPLY SINGLE PHASE 110V/220V

CD-1157

Figure 5 - Optional Mains Isolator: Installation Dimensions

Page 4.14

Issue 3

KH1207 Chapter 4 ELECTRICAL CONNECTIONS CABLE SPECIFICATIONS

28

Each ca ble is identified by a letter code which defines the type of ca ble required, e.g. Ca ble code N is a 38-core ca ble. Ta ble 1 provides specifications for each ca ble type. Ta ble 2 provides 38-core ca ble, colour code ab breviations. 29

The ca bles used to connect Kelvin Hughes equipment are to be to the following specification. Failure to use the correct specification ca bles may result in im paired equipment performance. TABLE 1 - CABLE SPECIFICATION CABLE

DESCRIPTION

CODE

CORE

DIAMETER  

E

12-core small multi-core

1344-722

16/0.2

10 mm 11 mm

H

14-core composite

45-762-0116-001

Mixed

18 mm

I

2 x 1.5 mm Power (low)

45-762-0173-001

1.5 mm

8 mm

K

2-core Power

1344-1123

1.5 mm

12 mm

 N

38-core small multi-core

5344-701

1.5 mm

17 mm

P

Co-axial (Low Loss) Type ECL 125

5344-719 (for long cable lengths only)

Varies

8.3 mm

R

12 core small composite

45-762-0041-001

Mixed

15.4 mm

38-Core Custom Built Cable

30

The 38-core com posite cable (KH code num ber 5344-701) is made for Kelvin Hughes and com prises the following: (1)

4 cores of 32/0.2 mm copper wire.

(2)

32 cores of 16/0.2 mm copper wire.

(3)

2 cores of co-axial cable.

12-Core Composite Cable

31

Issue 3

The 12-core com posite cable (KH code num ber 45-762-0041-001) is made for Kel vin Hughes and com prises the following: (1)

4 cores of 32/0.2 mm copper wire.

(2)

4 cores of 16/0.2 mm copper wire.

(3)

2 cores of 16/0.2 mm twisted and screened.

(4)

2 cores of co-axial cable.

Page 4.15

KH1207 Chapter 4 TABLE 2 - 38-CORE CABLE COLOUR ABBREVIATIONS ABBREVIATION

COLOUR  

R

RED

B

BLUE

G

GREEN

Y

YELLOW

W

WHITE

Bk

BLACK

Bn

BROWN

V

VIOLET

O

ORANGE

P

PINK

T or Lt/G

TURQUOISE or LIGHT GREEN

S

SLATE (grey)

R/B

RED/BLUE

R/G

RED/GREEN

R/Y

RED/YELLOW

R/W

RED/WHITE

R/Bk

RED/BLACK  

R/Bn

RED/BROWN

B/Y

BLUE/YELLOW

B/W

BLUE/WHITE

B/Bk

BLUE/BLACK  

B/O

BLUE/ORANGE

G/Y

GREEN/YELLOW

G/W

GREEN/WHITE

G/Bk

GREEN/BLACK  

G/O

GREEN/ORANGE

G/S

GREEN/SLATE

Bn/Bk

BROWN/BLACK  

Bn/Y

BROWN/YELLOW

Bn/W

BROWN/WHITE

S/B

SLATE/BLUE

S/Bn

SLATE/BROWN

V/Bk

VIOLET/BLACK  

V/Y

VIOLET/YELLOW

V/W

VIOLET/WHITE

G/B

GREEN/BLUE

 

 

WHITE CO-AX SLATE CO-AX  N/C

Page 4.16

NO CONNECTION

Issue 3

KH1207 Chapter 4 14 Core Composite Cable

32

The 14-core composite cable (KH code number 45-762-0116-001) is a Low Smoke and Fume cable, but not Zero Halogen, made for Kelvin Hughes, and comprises the following: (1)

Core function: 2

4 cores of 32/0.2 mm (1.0 mm ) copper wire. 2 1 screened twisted pair 16/0.2 mm (0.5 mm ) copper wire for serial data links. 2 3 twisted pairs in 1 screen 16/0.2 mm (0.5 mm ) copper wire for serial data links. 2 2 cores of co-axial cable 7/0.25 mm (0.35 mm ). (2)

Overall Screen The cable has an overall screen of close woven copper braid (tinned copper 91% minimum coverage) suitable for a high noise environment.

(3)

Outer Sheath The cable has a black outer sheath to withstand exposure to the outside environment, of salt air, rain, lubricating or diesel oil splashes, sun, snow, ice and some possible abrasion. The outer sheath is UV stable.

(4)

Conductor rating: 2

DC between conductors DC current Impedance Losses

2

1.0 mm 100 V 100 mA

0.5 mm 30 V 50 mA

Coaxial 15 V 75  <3 dB at 25 MHz up to 60 m

TABLE 3: 14-CORE CABLE COLOUR ABBREVIATIONS ABBREVIATION

Issue 3

COLOUR  

R

RED

B

BLUE

G

GREEN

Y

YELLOW

BN

BROWN

V

VIOLET

O

ORANGE

W

WHITE

S

SLATE (GREY)

Page 4.17

KH1207 Chapter 4 Small Multi-Core Cables

33

These ca bles conform to DEF STAN 61-12 (part 5). Each ca ble consists of a num ber of  insulated cores, collectively screened and clad in a PVC outer sheath.

34

Core Details (1)

The core details are as follows: Conductors consist of 16 strands of 0.2 mm diameter tinned copper wire. 2  Nominal cross-section area of conductor = 0.5 mm  Nominal diameter of conductor = 0.93 mm  Nominal thickness of insulation = 0.45 mm Minimum thickness of insulation = 0.40 mm Minimum diameter of core = 1.75 mm Maximum diameter of core = 1.90 mm

(2)

Braided Screen The cores are laid-up, covered with binding tape over which is woven a braiding of 0.2 mm diameter tinned copper wire.

(3)

Outer Sheath A PVC outer sheath is applied by extrusion over the wire braiding.

(4)

Maximum Current Rating The maximum current ratings are as follows: 2.5 A at 1000 V DC 2.5 A at 440 V AC at 1600 Hz

Power Cables

35

These ca bles are used for services requiring a moderate current carrying ca pacity, i.e. mains sup plies.

2-Core (Power):

Cable Code K:

KH Reference No. 1344-1123

250/440V grade:

7 x 0.67mm cores Cross linked polythene insulation  braided with 0.2mm diameter tinned copper wire, 79% coverage, low smoke, zero halogen outer sheath

Outer diameter:

Page 4.18

12 mm

Issue 3

KH1207 Chapter 4 Co-axial Cable

36

Where the distance between the Dis play and the Transceiver exceeds 60 metres, special co-axial ca bles and/or Sync and signal am plifiers may be required to obtain optimum results, consult Kel vin Hughes prior to installation of the cables. Co-axial Cable 75 ohms low loss (for extended cable runs)

Co-axial Cable: Inner Conductor: Dielectric: Screen: Overall Dia:

CODE No. 5344-719 Type ECL 125 (Manufacturer’s code) 1.25 mm Single Conductor   Air spaced Polyethylene Tape Screen 8.3 mm

Electrical Attenuation: Attenuation: Attenuation: Impedance:

Issue 3

60MHz 3.4dB/100m MAX 100MHz 4.9dB/100m MAX 200MHz 7.1dB/100m MAX 75 Ohm

Page 4.19

KH1207 Chapter 4 TRANSCEIVER 

37

Before starting electrical connection observe the following: WARNING ENSURE THAT ALL POWER SUPPLIES ARE ISO LATED BEFORE ANY ELECTRICAL CONNECTION TAKES PLACE.

38

(1)

Ensure that the associated display is turned off.

(2)

Remove fuses from mains isolators.

(3)

On Transceiver set ON/OFF switch to OFF.

The casing of the upmast transceiver must be securely earthed to the platform with  braided copper wire.

39

Allow sufficient length on all cables to allow for routing through the transceiver. Make sure that there is sufficient slack to allow for extreme movements during sudden shock to the vessel. 40

Before any electrical connections can be made, covers have to be removed from the following equipment: (1)

Upmast Transceiver.

(2)

Optional Mains Isolator.

(3)

Transmitter Interface Unit (if fitted).

(4)

40V Power Supply (if fitted).

41

To access the transceiver, remove the four captive screws securing the rear cover to the Upmast Transceiver and remove the cover.

42

To access the optional mains isolator, remove the cover by releasing the captive screw.

43

Ensure that all cables are secured to their associated entry point and that screened cables are earthed to their respective units.

Page 4.20

Issue 3

KH1207 Chapter 4 PCB Locations and Cableform Routing

44

Electrical connections for the downmast transceiver systems are deatiled in Figure 6 (for  full details of connections refer to the display system refer to your system manual (KH2020, KH2026 and KH2061), as appropriate). To fit cable proceed as follows:

 NOTE:

(1)

Remove gland nut, plastic washer and seal and discard washer.

(2)

Thread cable through back of gland housing for approx. 300 mm.

(3)

Remove cable outer covering (exposing braid) back as far as 15 mm from the gland housing.

(4)

Fold braid double to 80 mm from gland housing (remove excess).

(5)

Fit dished ring, spring and dished ring over the cable and onto the braid. The spring sits between the dished faces of the rings. The spring must contact the  braid when the gland nut is tightened.

(6)

Place seal over cable and onto outer covering at the gland housing.

(7)

Place plastic washer and gland nut over cable and screw assembly into gland housing and secure screening and cable with 'P' clip, unwrap paper insulation  back to screening and discard.

(8)

Connect wires as shown in Figure 7. The fitting kit contains Densotape, which is used to seal the cable entries.

Checks after Fitting

45

The upmast transceiver must be checked for security and for freedom of the antenna to rotate.

46

Ensure that all cables are secured to their associated entry point and that screened cables are earthed to their respective units.

47

All cable entries must be checked for signs of fretting, chafing or damage, and subsequently sealed with a mastic compound.

48

Commissioning instructions are described in Chapter 5.

Issue 3

Page 4.21

KH1207 Chapter 4

THIS PAGE INTENTIONALLY BLANK 

Page 4.22

Issue 3

KH1207 Chapter 4

8 1. REMOVEGLANDNUT, PLASTICWASHERAND SEALAND DISCARDWASHER.

1

TB2

2. THREADCABLE(1N) THROUGHBACK OF GLANDHOUSING FORAPPROX 300mm.

White (Video) Cable Strip back outer 35mm. Cut centre core to 10mm and fold 10mm of braid back over outer.

3. REMOVECABLEOUTER COVERING (EXPOSING BRAID)BACK AS FARAS 15mmFROM THEGLAND HOUSING. 4. FOLDBRAID DOUBLETO 80mmFROM GLANDHOUSING (REMOVE EXCESS). 5. PLACE SEALOVER CABLEAND ONTO OUTERCOVERING ATTHE GLANDHOUSING. 6. INSERTTHE TWO SCREENING FERRULES (10) BETWEENOUTERCOVERING ANDSCREENBRAID ATGLANDAS SHOWN. 7. PLACE GLANDNUT OVERCABLE ANDSCREW ASSEMBLYINTO GLANDHOUSING ANDSECURE SCREENINGAND CABLE WITH"P"CLIP, UNWRAPPAPERINSULATIONBACK TO SCREENING ANDDISCARD.

1

Casting

Grey (Sync) Cable Strip back outer 25mm. Cut centre core to 10mm and fold 10mm of braid back over outer.

Gland Rubber Seal Ferrule

ITEM

PACK QTY

1

2

1

2

2

1

TB2

PART No.

1

14

12

4

45-718-5144

45-718-5143

3

2

4

2

CDY-4031

5

2

CDY-A425

6

2

20-233-1101-27

7

2

20-282-5006-25

8

22

30-762-502-00

9

2

45-716-6027

10

2

CAE-4054

45-718-5163

MASS: 42Kg TOTAL (ARRAY:20Kg) (Tx/Rx : 22Kg)

FWD

Tx Monitor Arm

THREE M12 FIXING BOLTS (SUPPLIED AS PARTOF FITTING KIT)

Safety Switch CD-3731

Before any maintenance is carried out on the transceiver, isolate mains supply via external safety switch.

SAFETYSWITCH. BEFOREANY MAINTENANCEISCARRIED OUTTO TRANSCEIVER, ISOLATEMAINSSUPPLYVIA EXTERNALSAFETYSWITCH.

Figure 6

Issue 3

38-Core Composite Cable: Installation

Figure 6

Page 4.23/24

KH1207 Chapter 4

  -

            8             0   .             7             0   .             4             0

   1  .    R  .    S

   M    R    A    R    O    T    I    N    O    M

   1

   d   s   n   t   n   a   s   o    t    B  a   i     c    X   m  e   p    5   n   n    k   U  o    M    C

   R B

   0   1    2      2      0   0    O    V    3   3    E    A      k   A    D    I   -   E    V    M    E    A    A   4 3    C    F    C    &    L    P

   X    A    O    C    E    T    I    H    W

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   X    A    O    C    Y    E    R    G

   E   e   e    N   v   v    N    I   +     T    L    Y    D    S   S    G    H    R   N    D    N    R   R    T   N   N    N    A    I    I    E   E   E    U   O   O   O    E   E   E    D    T   T   T    V    V   V    V   I    M    M   M    A   A    V    N   R   N   N    A    7    7   7    5   M    E   E   U   5    2   V   2   2   V   V   1   Z   X   X    X    V   U   X   U   U   P   P   E    1   +   0  +  +   0   0  +   A   T   T    R    H   H   M   -   0   R   T   T   T   M    L   H    0   1   2    2   3    4    G    1 2   3   4   5 6   7   8 9 1   1 1    K   1   2 3 4 5 6   7 9   1   1 1    2    1    L    B    L    T    P    P

   k    B    /    Y    /    /   n   B    /    /    W    /    Y    k   G    /    W    /    W    W B   R   B   R   S   T   R   R   B   B   G

  n    B    /    R   B O R

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   k    B    /    B

   E    V   +    R    E    N    N    A    C    S 2

   E    V      R    E    N    N    A    C    S 3

4

5

6

7

  n   n   n   B    V    B    /    /    B    /   n   /    B    /    /    B    /    G    /    O    /    Y    G W   B   S   Y   W    S   S   Y B   V G   G

8

   k    R    B    /    C    G    S

   E    M    N    R    O    O   T   E    L    C    B   -    S    A    8    U    3    C    C    X    A    O    C    E    T    I    H    W

   X    A    O    C    Y    E    R    G

   k    O    B    W    G    /    Y    /    W    /    /    /    W    /    Y    /    /    S R   B   B   R   R   T G    B   G

   B    /    R

   k    k   B   n    /    B    B    /   n    k    /    R   B   W B   R O R   B

   k    B    / P V

  n    k    R   n   n   B    V    B    Y   /    B   /    B    C    /   n   /    B    /    /    B    /    G    /    O    /    /    G W   B   S   Y   W    S   S   Y B   V G   G   G    S

   1

   2    3    1    0      D    H    E

  S   E   H   G   U   H   N   I   V   L   E   K

KH1207 Chapter 4

  -

            8             0   .             7             0   .             4             0

   1  .    R  .    S

   M    R    A    R    O    T    I    N    O    M

   1

   d   s   n   t   n   a   s   o    t    B  a   i     c    X   m  e    5   p   n   n    k   U  o    C    M

   R B

   0   1    2      2      0   0    3    O    V    3   A    E      k   A    D    I      E    V    M    E    A    A   4 3    C    F    C    L    &    P

   X    A    O    C    E    T    I    H    W

   C    N    Y    S 2 1

   X    A    O    C    Y    E    R    G

   E   e   e    N   v   v    N    I   +     T    L    Y    R    S   S    D    G    H    D    N    R   R    T   N   N   N    N    I    A    I    E   E   E    U    O    O   O    E    E   E    D    T   T   T    V    V   V    V   M    M   M    A   A    V    N   R   N   N    A    7    7   7    5   I    M    E   E   U   5    2   V   2   2   V   V   1   Z   X   X    X    V   U   X   U   U   P   P   E    1   +   0  +  +   0   0  +   A   T   T    R    H   H   M  -   0   R   T   T   T   M    L   H    0   1   2    2   3    4    G    1 2   3   4   5 6   7   8 9 1   1 1    K   1   2 3 4 5 6   7 9   1   1 1    2    1    L    B    L    T    P    P

   k    B    W    G   /    B    Y   /    W    Y   /    W    /    /    k   /   n   /    /    W B   R   B   R   S   T   R   R   B   B   G

  n    k   k    B    B   B    /    /    /    /    O    R   B O R P V   R G

   k    B    /    B

   E    V   +    R    E    N    N    A    C    S 2

   E    V      R    E    N    N    A    C    S 3

4

5

6

7

  n   n   n   B    V    /   n   /    B   /    B   /    /    B   /    G    /    O    Y    /    B    /    G W   B   S   Y   W    S   S   Y B   V G   G

8

   k    R    B    /    C    G    S

   E    M    N    R    O    O   T   E    L    C    S    B      A    8    U    3    C    C

   B    A    B    A      U    I   6    T   6    A      R    N    N

   X    A    O    C    E    T    I    H    W

   X    A    O    C    Y    E    R    G

   O    F    E    K    D    I   S    V

   B    L    P    1 2   3 4 5 6 7 8 9   0   1   2   3   4    1   1   1   1   1    C    H    N   E   P   P   E   D   Y   Z   /    C   N   L   /    C   /    C   D    N    K    T   M   L   N   N    A    D    U    N    Y    O   H    S    U   I    A    N   M    N   N   G    R   U    S    T   E   E    M    X    N   R    R    U   X    T   T

   B    C    P    1    R    8    E    9    T    A    P      A    R    D    N    A    N    N    A    C

   O    E    E    K    D    I   S    V

   S    E    X    A    O    W    C

   k    G    /    B    /    /    Y    /    W    /    O    /    W    /    Y    /    W    S R   B   B   R   R   T G    B   G

   C    G    N    K    Y    S    S

   I    O    H   L    N   N    A   A    C   C    A    1 2    L    P

   W S

   T   D    O    E    T    N    A    N    N    I    E    E    M    R    R    C    E    T    S

   k    B    / P V

   B    L    P    1 2 3 4 5 6 7 8 9   0    1   e    V   V  e   v     v    5   5   +    1   1    V   +  -   S   S    V    7    0    R   R    E    2    R   +    E   T    T   A    R    O    T    A   E    O    A    E   H    T    L    H    A    U    L    D    U    O    D    M    O    M

   B    C    4    P    0    S    0    1    L    A    A      N    I   R    N    M    N    R    E T

   R    3    E    H    2    T    T    5    R    U    A    E      M    I   V    X    Z    N    T    A    C    O    C

   R    C    S S

   k    k   /   n    B    B    B    /   n    k    /    R   B   W B   R O R   B

   B    /    R

   1    2    1   Z   2   Z    L    Z   A   Z   A   L   H    A  n   A  n   H  n    2    L    P

1 2 3 4 5 6 7 8

   T    D    O    E    T    N    A    W    N    N    W    /    O    I    R   n   /    E   n    /    E    M    C    B   B   V V   O B    R    R    S    E    C    T    S

  n    k    R   n   n   B    V    B    /    /    B    /    B    /    C   n   /    B    /    /    B    /    G    /    O    /    Y    G W   B   S   Y   W    S   S   Y B   V G   G   G    S

   1

   2    3    1    0      D    H    E

  S   E   H   G   U   H   N   I   V   L   E   K

   C    L    2   3   4    P    1 2 3 4 5 6 7 8 9   0   1    1   1   1   1   1   e   v      R    E    N    N    A    C    S

  e   v   +    R    E    N    N    A    C    S

   1    0    0    U      S    1    4    P    0    S    0      N    I   0    9    A    6      M    5    4

   N    T    R    N   N    O   O    U   U    S   S    P   P    B   1 2 3 4    L    P

   Y G

   R    C    S

   E    M    H    R    O    E    O   T   L    S    C    B      A    4    U    C    1    C    H    R    C    O    T    S   I    S   W    E   S    C    R    O    E    R    T    P   N    I    O  r    T  o

   R    L N E    E    T    L    I    F

   R    C    R B    S

   R    E    W   I    O   E    P    L    E    B    R   A    O   C    C      2    E    S    A  ,   H   z   P    H    1    0   /    6   V    /    0   0    5   2    2    /    V    0    1    1

Figure 7 - Transceiver Connection Diagram

Issue 3

Page 4.25

KH1207 Chapter 4

THIS PAGE INTENTIONALLY BLANK 

Page 4.26

Issue 3

KH1207 Chapter 5

CHAPTER 5

COMMISSIONING CONTENTS Paragraph

1 5 5 7 10 11 12 13 13 14 15 16 17

Page

INTRODUCTION LINK AND SWITCH SETTINGS Transceiver SETTING TO WORK Systems with TIU only - Initial Checks All Systems Transceiver Terminals PCB HEADING LINE ADJUSTMENT General Checking the Alignment To Correct an Error (Fine Ad justment) To Correct an Error (Coarse Ad justment) PERFORMANCE MONITORING CHECKS

5.3 5.3 5.3 5.5 5.5 5.6 5.6 5.7 5.7 5.7 5.7 5.8 5.9

ILLUSTRATIONS Figure

1 2 3

Issue 3

Page

MkV with TIU: System Heater Circuit Transceiver Electronic Module Performance Monitor Dis play

5.6 5.10 5.11

Page 5.1

KH1207 Chapter 5

THIS PAGE INTENTIONALLY BLANK 

Page 5.2

Issue 3

KH1207 Chapter 5

CHAPTER 5

COMMISSIONING INTRODUCTION

1

After Installation, certain checks are required to bring the Antenna/Transceiver up to full working order. The majority of PCBs and Modules have been factory tested, and preset, and do not require any adjustment. However, certain setting up checks are needed to enable the set to become operational. 2

The installer must carry out the following procedures to commission the equipment.

3

Check that all cables have been installed and connected correctly.

4

Interswitched equipments, or equipments interfaced with other radar equipments, are described in their respective Hand books. CAUTION The transceiver RF output must not be operated into an open circuit or poorly matched feed cable. Damage to the RF head will result.

LINK AND SWITCH SETTINGS Transceiver

5

Ensure that the correct links are fitted to the Display Unit to enable it to work with the MkV Transceiver.

6

The Transceiver links are factory set. The links/switches listed below are options for the installation. All other links and switches are listed in the Workshop manual. Check that the MkV Transceiver links/switches are set as follows: a) Azimuth/Heading Line PCB CAE-A402/3: Azimuth PCB link set to 90 90 pulses per revolution  b) Antenna Terminals PCB CTX-A368: LK1 - A LK1 - B LK2 - MADE LK2 - OPEN

Issue 3

Antenna rotates on Run only Antenna rotates continuously Dummy sync pulse for Mute sector   No dummy sync for Mute sector  

Page 5.3

KH1207 Chapter 5 c) FET Modulator CTX-A332: Grid E1 F4 D4

 

Status MADE MADE OPEN

Function LK1 Heater current LK2 400V HT connected to power output stage LK3 Automatic Magnetron Current control circuit enabled LK4 Not used LK5 D3 OPEN Safety trips enabled LK6 D3 MADE Trigger pulse jitter. Enabled LK7 C1 MADE 75 ohm load connected allows modulator to run on its Internal trigger  Other links are soldered onto board to set current pulse width. SW1 A7 ON (Towards heatsink). HV supply enabled d) Receiver CTX-A356: LK1 LK2 LK3

LK4 LK5

LK6 LK7 LK8 LK9

Page 5.4

As factory set Tune sample delay (intermediate, approx 50 ns) As factory set Tune sample delay (maximum, approx 100 ns) As factory set Tune sample delay (minimum) (Note: only one of LK1, LK2 or LK3 is to be MADE. Selected for best AFC performance) NOT FITTED B MADE Minimum AFC lock   A MADE Intermediate AFC lock   A & B MADE Maximum AFC lock  A MADE 2 bandwidths. SP & MP wideband, LP and VLP narrowband OPEN X band. Minimum Vco gain OPEN X band for +5 V supply MADE Sets regulator output to +5V

Issue 3

KH1207 Chapter 5 SETTING TO WORK 

7

For all systems, carry out the following: (1)

Switch on the single phase mains at the Isolators for the Display and Transceiver.

(2)

Set the display power switch to ON.

(3)

If a 40V Power Supply is fitted set the ON/OFF switch on top of the unit to ON.

(4)

If a TIU is fitted set the ON/OFF switch on the top of the unit to ON.

8

At the display ensure that the Transceiver is entered as MkV in the installed equipment  parameters.

9

Verify that the display indicates TX READY after the warm up period of approximately 60 seconds.

Systems with TIU only - Initial Checks

10

For systems fitted with a TIU, the heater current must be measured and links adjusted as required. To do this carry out the following (refer to Figure 1): (1)

Issue 3

Set the TIU power supply switches SW1

SW2

CAE-A30-20

ON (9.9V)

ON (26V)

Low speed

CAE-A30-21

ON (9.9V)

OFF (36V)

High speed

(2)

To measure the heater current connect an ammeter in series with wire from the TIU Terminals PCB (NNR-A1004) pin 3.

(3)

Switch the system ON. KEEP AT STANDBY ONLY. DO NOT SWITCH TO RUN.

(4)

The Heater Current is to be between 0.56A and 0.6A.

(5)

If it is low, Switch system OFF, and short out R1 on TIU Terminals PCB (NNR-A1004) (either solder a wire link across R1 or set LK1 to position A if  there is one).

(6)

Switch the system ON.

(7)

If the current is still low, switch the system OFF and make link LK1 on the Transmitter Modulator PCB (CTX-A332).

Page 5.5

KH1207 Chapter 5 (8)

Switch the system ON. Once the heater current is correct, switch the system OFF.

TRANSMITTER INTERFACE UNIT NNR-A66

Mk 5 TRANSCEIVER CAE-A30-7, -8, -20, -21 TERMINALS PCB CTX-A368

TERMINALS PCB NNR-A1004

POWER SUPPLY UNIT 45-677-124

A +9.9V ±0.4V 0V

1R0

LK1

MODULATOR PCB CTX-A332 (NORMALLY OPEN)

LK1

B PLB-3 PLB-4

2

A

+ve WIRE V DROP (0.5mm ) 22.6mV/METRE @ 0.58A -ve WIRE V DROP, VERY LOW DUE TO MULTI-PATH CONNECTIONS

+V PLG-1

1R0

0V PLG-2 FILTER INDUCTOR

PULSE TRANSFORMER (1R5) 5.7V to 6.9V Gn Y

MAGNETRON

5.7V to 6.9V PULSE TRANSFORMER (1R5)

HEATER SENSE (0R33)

CD-6943

ISSUE 1

Figure 1 - MkV with TIU: System Heater Circuit All Systems

11

Set display to RUN Transceiver.

Transceiver Terminals PCB

12

This PCB requires no adjustments apart from the setting up of links.

Page 5.6

Issue 3

KH1207 Chapter 5 HEADING LINE ADJUSTMENT

 NOTE: This procedure is not required for Nucleus 3, Manta or MantaDigital displays. Heading  line errors are corrected at the Display 'skew' setting. General

13

Following installation, the heading line may be checked to give maximum bearing accuracy as follows:

 NOTE: During the Heading Line alignment procedure, the ship must be stationary on a fixed  known heading and must have bearing information from the gyro compass available. The ship is to be alongside; less accurate results are obtained if at anchor or at a buoy. Checking the Alignment

14

With the vessel stationary, or at anchor, proceed as follows: (1)

Check that the array/gearbox alignment mark  is correct.

(2)

Switch ON the Display and operate in a HEAD UP mode and at a range of 6 miles.

(3)

Select a stationary target which can be seen by eye and which paints an echo on the screen.

(4)

Take a compass bearing on the target, and compare this with the bearing of the echo paint on the display. Note the degree and direction of discrepancy.

To Correct an Error (Fine Ad justment)

15

Any error is present in the Head ing Line may be ad justed as follows: (1)

Switch the Gearbox Safety Switch to OFF.

(2)

Switch all supplies to STANDBY.

(3)

Remove the four captive screws securing the cover to the rear of the Turning Mechanism and remove the cover.

(4)

Loosen the Azimuth/Heading Line PCB locking screws, refer to Figure 1.

(5)

Note the position of the pointer on the scale, which is marked in two degree steps.

 NOTE: Moving the PCB to the left moves the video anti-clockwise with respect to the Heading    Line.

Issue 3

(6)

Remove the error by sliding the PCB by the number of degrees to correct the misalignment.

(7)

Retighten the Azimuth/Heading Line PCB.

(8)

Refit the outer cover.

Page 5.7

KH1207 Chapter 5 (9)

Set the Safety Switch to ON.

(10)

Set the Display to RUN and check that the visual and PPI display bearing of the known target.

(11)

To make any further adjustment repeat step (6).

(12)

Secure the rear cover.

To Correct an Error (Coarse Ad justment)

16

The Heading Line Opto Disc is factory set, however if the fine adjustment does not achieve the required correction, proceed as follows: (1)

Perform Paragraph 14, steps (1) to (3).

(2)

Disconnect the plug to the Heading Line PCB.

(3)

Remove the Heading Line PCB, ensuring that the opto sensor does not foul against the opto disc.

(4)

With the array facing forward, check that the leading edge of the heading line disc recess is in line with the array centre line.

(5)

The heading line disc recess may be corrected by slackening the three M4 retaining bolts holding the disc in place. Do not remove the bolts completely.

(6)

Manually rotate the disc to the new position required and retighten the bolts.

(7)

Refit and reconnect the Heading Line PCB by sliding the opto device over the edge of the opto disc.

(8)

Refit the retaining pillars and reconnect the plug.

(9)

To check that the Heading Line is correct, refer to the Fine Adjustment Paragraph.

Page 5.8

Issue 3

KH1207 Chapter 5 PERFORMANCE MONITORING CHECKS

17

The efficiency of the magnetron is checked by carrying out a performance monitor  check.

18

The two specific types of optional performance monitors that can be fitted are:

19

Issue 3

(1)

Transmission Monitor - comprises a monitor arm fitted to the outer case of the scanner unit. The transmission monitor is selected by setting PERF. MON to ON at the display. The monitor arm neon is ionised as the antenna passes over the arm, and a ‘plume’ is displayed on the screen.

(2)

Receiver Monitor  - comprises a resonant cavity with an adjustable plunger, which is factory set according to magnetron frequency. It is fitted t o the rotating  joint waveguide. The receiver monitor is selected by setting PERF.MON to ON at the display and is displayed as a ‘sun’ in the centre of the screen.

To carry out the performance monitor check, proceed as follows (refer to Figure 3 for  typical displays): (1)

Switch the display power to ON.

(2)

After the Tx warm-up period, the screen should indicate TX READY, select GO TO RUN.

(3)

Select 1.5 mile range and PERF.MON, (this should also be indicated - top left hand side of the Nucleus screen).

(4)

Ensure that the picture is correctly tuned.

(5)

By using the VRM facility, measure the diameter of the radar sun that appears in the centre of the display.

(6)

Record the diameter of the sun in the operators record under the PERFORMANCE MONITOR heading in the RX.... nm.   This data must be recorded as it will be used to identify degradation in performance.

(7)

Select the 12 mile range.

(8)

Using the VRM facility, measure the length of the plume (at a bearing of  approximately 210 degrees from the heading line) and record as in (6) under  TX.........nm. Heading. This data must be recorded as it will be used to identify degradation in performance.

Page 5.9

KH1207 Chapter 5

PIN DIODE DRIVER & LIMITER CTX-A512 LNFE WITH SHIM FILTER BETWEEN THE LNFE & THE PIN DIODE DRIVER & LIMITER

AZIMUTH PCB CAE-A402-3

CIRCULATOR RETAINING SCREWS

PIN DIODE DRIVER PCB

CIRCULATOR ASSEMBLY 45-646-604 RF FILTER

Rx MONITOR CAVITY CTX-A173 SECTOR MUTE PCB CTX-A162 (OPTIONAL)

   W    k    3    1

MODULATOR PCB COVER

   R   E    E   G    A    T    G   L    O    N   V    G    A   H    I    D   H

Tx MONITOR PCB (OPTION) UNDER CHASSIS

CD-3835

TRANSCEIVER TERMINALS PCB CTX-A368 CHASSIS RETAINING SCREWS TB2

ISSUE 2

Figure 2 - Transceiver Electronic Module

Page 5.10

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KH1207 Chapter 5 010

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Figure 3 - Performance Monitor Display

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KH1207 Chapter 5

THIS PAGE INTENTIONALLY BLANK 

Page 5.12

Issue 3

KH1207 Chapter 6

CHAPTER 6

MAINTENANCE CONTENTS Paragraph

1 2 2 5 5 6 7 8 11 12 13 16 19 20 21 22 23 26 28 28 29 30 31 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Issue 3

INTRODUCTION PLANNED MAINTE NANCE PERFORMANCE CHECKS - MONTHLY OR ON BEFORE LEAVING PORT SIX MONTHLY CHECKS Antenna Transceiver Casing Inspection Tx Monitor Arm Antenna Motor/Gear box DIAG NOSTIC MAINTE NANCE PRE-REQUISITES FAILURE MESSAGES PERFORMANCE CHECK DEGRADATION TEST EQUIPMENT PREPARATION FOR FAULT DIAG NOSIS TEST POINTS CORRECTIVE MAINTE NANCE GAINING ACCESS TO THE TRANSCEIVER PCBS AND MODULES LOCATION OF PCBS AND MODULES IN THE TRANSCEIVER REPLACING MODULES IN THE TRANSCEIVER Removal of Transceiver Terminals PCB (CTX-A368) Re placement of Transceiver Terminals PCB (CTX-A368) Removal of Modulator PCB Assem bly (CTX-A332) Re placement of Modulator PCB Assem bly (CTX-A332) Removal of Receiver PCB (CTX-A356) Re placement of Receiver PCB (CTX-A356) Removal of Azimuth PCB (CAE-A402/3) Re placement of Azimuth PCB (CAE-A402/3) Removal of Magnetron Assem bly (CTX-A197) Re placement of Magnetron Assem bly (CTX-A197) Removal of Circulator Assem bly (45-646-604) Re placement of Circulator Assem bly (45-646-604) Removal of PIN Diode Driver and Limiter (CTX-A512) Re placement of PIN Diode Driver and Limiter (CTX-A512) Removal of Low Noise Front End Assem bly (CTX-A515) Re placement of Low Noise Front End Assem bly (CTX-A515) Removal of Transmitter Monitor PCB (CTX-A198) Re placement of Transmitter Monitor PCB (CTX-A198) Removal of Sector Mute PCB (CTX-A162) Re placement of Sector Mute PCB (CTX-A162) Removal of Receiver Monitor Cavity (CTX-A173) Re placement of Receiver Monitor Cavity (CTX-A173) Removal of Monitor Arm (CAE-A147) Re placement of Monitor Arm (CAE-A147) Removal of Motor (Low Speed (CAE-A30-20)) Re placement of Motor (Low Speed (CAE-A30-20))

Page

6.3 6.3 6.3 6.5 6.5 6.6 6.6 6.6 6.7 6.7 6.7 6.8 6.8 6.9 6.10 6.16 6.17 6.17 6.18 6.18 6.18 6.18 6.19 6.19 6.20 6.20 6.20 6.21 6.21 6.22 6.22 6.22 6.23 6.23 6.23 6.23 6.23 6.24 6.24 6.24 6.24 6.25 6.25 6.25 6.25

Page 6.1

KH1207 Chapter 6 CONTENTS (continued) Para

Page

55 56 57 58 59 60 61 62 63 65 66 67 68 69 70 71

Removal of Motor (High Speed (CAE-A30-21)) Re placement of Motor (High Speed (CAE-A30-21)) Removal of the Brushless Motor PCB (CAE-A236 (High Speed Motor)) Re placement of the Brushless Motor PCB (CAE-A236 (High Speed Motor)) Removal of +26V Motor Starter Assem bly (CTX-A359 (Low Speed Motor)) Re placement of +26V Motor Starter Assem bly (CTX-A359 (Low Speed Motor)) Removal of Rotating Joint Re placement of Rotating Joint CHECKS AFTER UNIT REPLACEMENT Modulator PCB Transceiver Terminals PCB Azimuth PCB Magnetron Assem bly Low Noise Front End Diode Limiter Receiver Monitor Cavity

6.26 6.26 6.26 6.26 6.27 6.27 6.27 6.28 6.29 6.29 6.30 6.30 6.30 6.31 6.31 6.31

TABLES Table

1 2

Page

LOCATION OF PCBs AND MODULES LOCATION OF OPTIONAL PCBs AND MODULES

6.17 6.18

ILLUSTRATIONS Figure

1 2 3 3 4 5 6 7 8 9 10

Page

Transceiver Terminals PCB : Test Point Location Modulator PCB : Test Point Location MkV Transceiver: Fault Diagnosis (Sheet 1 of 2) MkV Transceiver: Fault Diagnosis (Sheet 2 of 2) Transceiver Electronics Module: Access Transceiver Electronics Module Location of Motor Starter PCB (CAE-A30-20 only) Location of Brushless Motor PCB (CAE-A30-21 only) Assembly of Transceiver: Component Location MkV with TIU: System Heater Circuit Performance Monitor Display

Page 6.2

6.11 6.13 6.14 6.15 6.33 6.34 6.35 6.36 6.37/38 6.39 6.40

Issue 3

KH1207 Chapter 6

CHAPTER 6

MAINTENANCE INTRODUCTION

1

This Chapter is divided into three parts: (1)

Planned Maintenance.

(2)

Diagnostic Maintenance.

(3)

Corrective Maintenance. PLANNED MAINTENANCE

WARNING THIS EQUIPMENT IS NOT FITTED WITH SAFETY INTERLOCKS AND LETHAL VOLTAGES ARE PRESENT WITHIN THE UNIT. ACCESS TO THE INTERIOR OF THE TRANSCEIVER IS ONLY TO BE CARRIED OUT BY A QUALIFIED TECHNICIAN. PERFORMANCE CHECKS - MONTHLY OR ON BEFORE LEAVING PORT

2

The efficiency of the magnetron and receiver circuits is checked by carrying out a  performance monitor check.

3

The two specific types of optional performance monitors that can be fitted are:

4

Issue 3

(1)

Transmission Monitor - comprises a monitor arm fitted to the outer case of the scanner unit. The transmission monitor is selected by setting PERF. MON to ON at the display. The monitor arm neon is ionised as the antenna passes over the arm, and a ‘plume’ is displayed on the screen.

(2)

Receiver Monitor  - comprises a resonant cavity with an adjustable plunger, which is factory set according to magnetron frequency. It is fitted t o the rotating  joint waveguide. The receiver monitor is selected by setting PERF.MON to ON at the display and is displayed as a ‘sun’ in the centre of the screen.

To carry out the performance monitor check, proceed as follows: (1)

Switch the display power to ON.

(2)

After the Tx warm-up period, the screen should indicate TX READY, select GO TO RUN.

(3)

Select 1.5 mile range and PERF.MON, (this should also be indicated - top left hand side of the Nucleus or Manta screen).

(4)

Ensure that the picture is correctly tuned.

Page 6.3

KH1207 Chapter 6 (5)

By using the VRM facility, measure the diameter of the radar 'sun' that appears in the centre of the display.

(6)

Record the diameter of the 'sun' in the operators record under the PERFORMANCE MONITOR heading in the RX.... nm.   This data must be recorded as it will be used to identify degradation in performance.

(7)

Select the 12 mile range.

(8)

Using the VRM facility, measure the length of the 'plume' (at a bearing of  approximately 210 degrees from the heading line) and record as in (6) under  TX.........nm. Heading. This data must be recorded as it will be used to identify degradation in performance.

(9)

Compare the results with those previously recorded. If there is a significant degradation since the last reading, refer to the Fault Diagnosis section of this chapter (paragraph 11). 350

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SIX MONTHLY CHECKS CAUTION Always switch the radar OFF, and as an additional precaution, switch OFF the antenna safety switch when working on the transceiver or antenna. Antenna

5

Visually check the front radiating window for damage and soot or dirt. Note that even a thin layer of soot or dirt can cause serious loss of radar performance. If necessary, CAREFULLY wipe the antenna front radiating window using soap and water and a soft non-abrasive cloth. Ensure the window is not scratched or damaged when carrying out this  procedure. CAUTION NEVER PAINT the front radiating window.

Issue 3

Page 6.5

KH1207 Chapter 6 Transceiver Casing Inspection

6

Visually inspect that all screws, nuts and bolts are secure and free from corrosion.

Tx Monitor Arm

7

Check the following: (1)

The Monitor Arm is securely fitted.

(2)

Visually check the Monitor Arm bulbous end for soot and dirt. If necessary, CAREFULLY wipe the bulbous end using soap and water and a soft non-abrasive cloth.

Antenna Motor/Gearbox

8

The antenna motor brushes should be checked every 6 months or 3000 hours, whichever  is sooner. At the same time, check the commutator for wear. To check, proceed as follows: (1)

Remove the Transceiver Electronic Module, as detailed in paragraph 20.

(2)

Remove the Motor from the Transceiver case.

(3)

Remove brushes from housing and check for wear, replace with new brushes if  necessary.

(4)

Refit brushes, ensuring brush retaining springs are in place, and refit Motor into Transceiver case.

9

The gearbox is lubricated at the factory, and should not normally require attention.

10

Check that the antenna gearbox mounting bolts are secure and kept free of corrosion

 NOTE: The high speed antenna uses a brushless motor and requires no maintenance.

Page 6.6

Issue 3

KH1207 Chapter Chap ter 6 DIAG DI AGNOS NOSTIC TIC MAINTE MAINTENANCE NANCE WARNING THIS EQUIPMENT EQUIPMENT IS NOT FITTED WITH SAFETY INTER IN TERLOCKS LOCKS AND LETHAL LE THAL VOLTAGES ARE A RE PRESENT PRES ENT WITHIN THE UNIT. ACCESS AC CESS TO THE INTE IN TERIOR RIOR OF THE TRANSCEIVER TRANSCEIVER IS ONLY TO BE CARRIED OUT BY A QUALIFIED QUAL IFIED TECHNI TECHNICIAN. CIAN.

 NOTE: Repair to the transceiver should only be undertaken by qualified qualified service engineers or  Kelvin Hughes and their approved agents. Unauthorised repair of equipment during the Warranty period will invalidate the Warranty. 11

The flo flow w charts charts in this this cha chapte pterr provid providee an aid to faul faultt diagn diagnosi osiss on the tran transcei sceiver ver/tur /turnin ning g mechanism. The flow charts enable fault diagnosis down to module level and also identify wiring faults. Entry to the flow charts is via Failure Messages generated generat ed by the display. PRE-REQUI PRE-REQ UISITES SITES

12

The dia diagno gnostic stic rou routin tines es in the flo flow w char charts ts assum assumee that that the rad radar ar has bee been n work working ing,, and and that the system is set up for normal operation at the time the fault occurred.

FAILURE FAIL URE MESSAGES MESSAGES

13

14

Isssue 3 Is

The fol follow lowing ing fail failure ure mes messag sages es may may be app appear ear on the data fiel field d of of the the disp display lay mon monito itorr if  certain signals are missing: (1)

No Sync - the sync pulses from the transceiver are not being detected at the display.

(2)

No Video - the radar video from the transceiver is not being detected at the display.

(3)

No Azimuth - the azimuth pulses from the transceiver are not being detec ted at the display.

(4)

No Heading Line - the heading line pulses from the transceiver are not being detected at the display.

Check tha Check thatt the the transc transceiv eiver er and and asso associat ciated ed equi equipm pment ent is switc switched hed on and tha thatt the the antenn antennaa is rotating, as follows: (1)) (1

Ensu En sure re any any as asso soci ciat ated ed Mai Mains ns Iso Isola lato torr is sw swit itch ched ed on. on.

(2)

If a TIU is fitte fitted, d, ensu ensure re it is switch switched ed on. on. If it is swit switched ched on, che check ck the the fuse fuse in the the Power Supply is intact, and replace if necessary (fuses c an sometimes fail due to age or a transient power surge). If the new fuse fails then there is a fault in the system.

(3)) (3

If the the 40V 40V Pow Power er Sup Suppl ply y is fitt fitted ed,, ensu ensure re it is is switc switche hed d on, on, and and the the MAIN MAINS S ON and MOTOR ON LEDs on the top of the unit are lit.

Page 6.7

KH1207 Chapter Chap ter 6 WARNING ALWAYS SWITCH THE RADAR OFF AT THE DISPLAY BEFORE WORKING ON THE ANTENNA OR TURNING MECHANISM. THIS IS ESSENTIAL TO PREVENT THE ANTENNA FROM ROTATING AND RADIATING RF.

(4)) (4

15

If the the ant anten enna na is is not not rotat rotatin ing g chec check k that that the the safe safety ty swi switch tch on the the base base of the the transceiver is switched on. If it is switched off, DO NOT switch on until the Radar is switched OFF at the display as the antenna may suddenly start to rotate.

If th thee abo above ve ar aree OK, OK, th ther eree is is a fa faul ultt in in th thee sys syste tem m.

PERFOR PER FORMANCE MANCE CHECK DEGRA DEGRADA DATION TION

16

If the the perfo perform rmance ance of you yourr radar radar has dete deterio riorate rated, d, and the there re are are no no failu failure re messa messages ges,, carry carry out the performance monitor check detailed in para graph 2 of this chapter and compare the readings with those documented on installation and at the last routine check. 17

If the the Tx Tx Moni Monito torr Plum Plumee is <50 <50% % of the the ori origi gina nall logg logged ed valu valuee (the (the readi reading ng tak taken en at at installation), or the Rx Monitor Sun is <10% of the original logged value (the reading taken at installation) a fault f ault is present in the transceiver. tra nsceiver. Lower levels of degradation may occur, which can cause performance problems. 18

Note the following: (1)) (1

Whet Wh ethe herr the the degr degrad adat ation ion is in in the the 'plu 'plume me'' or th thee 'sun 'sun'' or or both both..

(2)

If ther theree is a signi significa ficant nt deg degrada radation tion in the the 'pl 'plum ume', e', the tran transmi smitter tter pow power er has has reduced. The most likely cause of this is aging of the magnetron, and this will need to be replaced. Note that magnetrons are lifed items and as soon as significant degradation is detected, a visit to your ship by a service engineer  should be arranged to check the transceiver, and if necessary replace the magnetron.

(3)

If ther theree is sign signifi ificant cant deg degrada radatio tion n in the 'su 'sun', n', ther theree is lik likely ely to be a fau fault lt in in the the receiver circuits.

TEST EQUIPMENT

19

Routinee field Routin field mai mainte ntenan nance ce req requir uires es fau fault lt loca locatio tion n down down to mod module ule rep replace lacemen mentt leve level. l. The only test equipment required for fault finding is a high impedance Multimeter.

Page 6.8

Issue 3

KH1207 Chapter Chap ter 6 PREPA PREP ARA RATION TION FOR FAULT DIAG DIAGNO NOSIS SIS WARNING WARNING THIS EQUIPMENT EQUIPMENT IS NOT NO T FIT TED WITH SAFETY INTER TERLOCKS LOCKS AND LETHAL LE THAL VOLTAGES ARE PRESENT PRESENT WITHIN THE UNIT. ACCESS AC CESS TO THE INTE IN TERIOR RIOR OF THE TRANSCEIVER TRANSCEIVER IS ONLY TO BE CARRIED CARRIED OUT BY A QUALIIFIED TECHNI QUAL TECHNICIAN. CIAN. THE EXTER EXTERNAL NAL ISOLA LATION TION SWITCH, LOCATED LOCATED ON THE TRANSCEIVER  TRANSCEIVER  CASING, CAS ING, ONLY REMOVES REMOVES THE RUN CONTROL CONTROL AND THE +24V AERIAL MOTOR START SIG SIGNAL. NAL. CAUTIONS CAU TIONS Handling Han dling Of Electro Electrostatic static Sensi Sensitive tive Semicon Semiconduc ductor tor Devices. Devices. (1)

Semicon conduc ductor tor devices devices used in the equipment equip ment are lia liable to damage damage due to static voltage. volt age. Observe Observe the follow fol lowing ing precau precautions tions when handling handling these devices devices in their unterminated state, or modules mod ules contain containing ing these devices. de vices. Persons remov Persons removing ing modules modules from an equipment equipment using using these devices devices should be earthed by a wrist strap and a re sis sistor. tor. Soldering Solder ing irons used during dur ing repair repair oper opera ations must be low voltage volt age types with earth tips and isolated iso lated from the mains voltage volt age by a double double insu in sulated lated transformer. transformer. Outer clothing clothing worn must be unable un able to gener generate ate static voltages. volt ages. Printed Circuit Circuit Boards (PCBs) fitted fit ted with these devices de vices must be stored and transported transported in anti-static bags. Fit new devices devices in a special spe cial handling handling area. For detailed detailed infor forma mation, tion, refer refer to British British Standard Standard BS 5783 or other equiva equiv alent standard. standard.

(2)

Open wave Open wavegui guides des mus mustt be be kept kept free free of dirt dirt and moi moiss ture by using using plastic plastic aper ap erture ture seals when left unat un attended. tended.

(3)

Use non-magnetic tools when working near the magnetron.

Isssue 3 Is

Page 6.9

KH1207 Chapter 6 20

To access the units inside the transceiver it is necessary to remove the transceiver cover. To gain access to the PCBs and Modules: (1)

Remove the four captive screws securing the end cover to the rear of the Transceiver and remove cover.

(2)

Disconnect Plugs PLF, G, K, M and L from the Transceiver Terminals PCB.

(3)

Remove the four screws securing the RF Head to the Rotating Joint.

(4)

Remove the two bolts securing the Transceiver Electronics Module to the sliding rails.

(5)

The Transceiver Electronics Module may now be removed from the Transceiver.

 NOTE: Whenever the end cover casting is removed for access to the units inside the transceiver, before replacement ensure the casting seal is clean and clear of obstacles. Check that all the screws are secure whilst the casting end cover is removed. Whenever the Transceiver Electronic Module is removed, inspect the input cable connections, look for worn seals/grommets, traces of water, loose connections and  strands of wire. TEST POINTS

21

Test Points are located on the following PCBs: (1)

Transceiver Terminals PCB

TP1 TP2 TP3 TP4 TP5 TP6

Page 6.10

Dummy Sync pulse astable output Gated sync pulses Video output Sync Output Rx Sync from Modulator   0V (signal)

Issue 3

KH1207 Chapter 6

TP1

TP2

TP5    B

PLA

   2    K    L

   1    K    L    A

PLC

PLE

PLD

TP3

TP4

PLF

PLG

PLK

   6    P    T

PLL

PLN

PLM

1

CD-3839

Figure 1 - Transceiver Terminals PCB : Test Point Location

Issue 3

Page 6.11

KH1207 Chapter 6 (2)

Modulator PCB

TP1 - TR1 gate drive pulse TP2 - High Voltage Sup ply TP3 - TR5 gate drive pulse TP4 - MODSYNC out TP5 - HV Current Monitor  TP6 - HV Current trip reference level TP7 - Common for TP5 TP8 - High Voltage Current trip level TP9 - HV Current trip pulse TP10 - LV Current trip reference level TP11 - Magnetron Heater Current Monitor  TP12 - LV Current trip fixed reference level TP13 - LV Current trip Shut down pulse TP14 - HTLO monitor out put TP15 - Pulse transformer power drive pulses TP16 - Tail biter pulse TP17 - Main FET drive pulses TP18 - Power ground TP19 - Low if 350V Line is over 450V TP20 - Low voltage sup ply, nominally +14V TP21 - Pulse shaper circuit drive pulses TP22 - MOD_TRIG from micro-controller  TP23 - LPRE_PULSE out put TP24 - Enable high voltage TP25 - Drive pulse to CTX-A339

Page 6.12

Issue 3

KH1207 Chapter 6

TP15

TP17

PLD TP16

TP11 TP14 TP4

TP25 TP20

TP2 TP8 TP18

TP7

TP13 TP9

PLC

TP5 TP6

TP12 TP19 TP10

TP22

TP3 TP1 TP21

   E    L    P

TP24

PLA

PLB

CD-3721

Figure 2 - Modulator PCB : Test Point Location

Issue 3

Page 6.13

KH1207 Chapter 6

RADAR FAULT DETECTED AT DISPLAY (AT STANDBY)

ENSURE DISPLAY IS SWITCHED ON

NOTE: CANBUS FOR TIU. PARALLEL FOR DIU OR SINGLE SYSTEM.

IS Tx READY INDICATED 60s AFTER TRANSCEIVER SWITCHED ON AT DISPLAY?

NO

YES

IS DISPLAY INSTALLATION MENU SET CORRECTLY TO CANBUS OR PARALLEL?

NO

SET UP INSTALLATION MENU CORRECTLY

YES

AT DISPLAY SET TRANCEIVER TO RUN

AT DISPLAY SET TRANCEIVER TO RUN

IS RADAR PICTURE OK?

YES

CHECK TEST MENU SETTING FOR Tx READY THRESHOLD (TRANSCEIVER IS READY, BUT NOT INDICATED AT DISPLAY)

NO

WEAK SIGNALS IS A FAILURE MESSAGE DISPLAYED ON THE DISPLAY?

NO

USE Tx & Rx MONITORS FOR DIAGNSOSIS. SET Tx PERFORMANCE MONITORS TO ON.

YES

TO SHEET 2

IS Tx MONITOR PLUME REDUCED TO <50% OF LOGGED VALUE?

NO

YES

SUSPECT:  DIRTY/DAMAGED ANTENNA, DAMAGED WAVEGUIDE, WATER IN WAVEGUIDE, MAGNETRON POWER OUTPUT REDUCED,

IS Rx MONITOR SUN REDUCED TO <10% OF LOGGED VALUE?

NO

SIGNAL LEVELS MAY BE LOW GIVING SOME DEGREDATION. BUT STILL WITHIN ACCEPTABLE RANGE.

YES FAULTY LIMITER GIVES POOR SIGNALS, FAULTY LNFE CAN GIVE NO OR VERY POOR SIGNALS, FAULTY LOGARITHMIC RECEIVER PCB CAN GIVE POOR TUNING & POOR SIGNALS

NOTE: THE MODULATOR CAN SOUND AS IF IT IS TRIGGERED BUT THE MAGNETRON MAY NOT BE TRUE

CD-7013

ISSUE 1

Figure 3 - MkV Transceiver: Fault Diagnosis (Sheet 1 of 2)

Page 6.14

Issue 3

KH1207 Chapter 6

FROM SHEET 1

IS THERE POWER FOR THE TRANSCEIVER AND MOTOR 26V 24RPM OR 36V/40V 40RPM IF FITTED?

NO

SUSPECT DISPLAY / 40V PSU / TIU FAULT AS APPROPRIATE

YES

FAILURE MESSAGE

FAILURE MESSAGE

NO SYNC/NO VIDEO ON DISPLAY

NO AZIMUTH/  NO HEADING LINE ON DISPLAY

IS THE COAXIAL PLUG CONNECTED ON THE TERMINALS PCB?

NO

RECONNECT CABLE

YES

ARE THE RECEIVER/MODULATOR CONNECTIONS PLUGGED IN?

IS THE ANTENNA ROTATING?

NO

YES

NO

RECONNECT

NO

SET THE ANTENNA SAFETY SWITCH TO ON?

YES

NOTE: FOR THE HIGH SPEED MOTOR THIS IS THE SWITCHING WAVEFORM, REFER TO IS THERE CHP 4 FOR DETAILS POWER TO THE

ANTENNA TURNING MOTOR/  MOTOR PCB OR STARTER ASSY?

YES

VIDEO/NOISE PRESENT AT TP3 ON TERMINALS PCB?

IS THE ANTENNA SAFETY SWITCH SET TO ON?

NO

CHECK WIRING

YES

NO

REPLACE THE MOTOR/  BRUSHLESS MOTOR PCB OR STARTER ASSY

TERMINALS PCB FAULT

YES

SUSPECT DISPLAY PCBs

NOTE: HL OUTPUT IS A +ve ARE AZ/HL BLIP ON A VOLTMETER, PULSES PRESENT AT THE AZ OUTPUT IS A +ve TERMINALS PCB? VOLTAGE ON A VOLTMETER

NO

SUSPECT DISPLAY PCBs OR HEADING LINE PCB IN THE TURNING MECHANISM

YES

CHECK WIRING CONNECTIONS. SUSPECT AZ/HL PCB IN THE TURNING MECHANISM

CD-7014

ISSUE 1

Figure 3 - MkV Transceiver: Fault Diagnosis (Sheet 2 of 2)

Issue 3

Page 6.15

KH1207 Chapter 6 CORRECTIVE MAINTENANCE WARNING THIS EQUIPMENT IS NOT FIT TED WITH SAFETY INTERLOCKS AND LETHAL VOLTAGES ARE PRESENT WITHIN THE UNIT. ACCESS TO THE INTERIOR OF THE TRANSCEIVER IS ONLY TO BE CARRIED OUT BY A QUALIFIED TECHNICIAN.   (1)

CAUTIONS

Handling Of Electrostatic Sensitive Semiconductor Devices. Semiconductor devices used in the equipment are liable to damage due to static voltage. Observe the following precautions when handling these devices in their unterminated state, or modules containing these devices. Persons removing modules from an equipment using these devices should be earthed by a wrist strap and a re sistor. Soldering irons used during repair operations must be low voltage types with earth tips and isolated from the mains voltage by a double insulated transformer. Outer clothing worn must be unable to generate static voltages. Printed Circuit Boards (PCBs) fitted with these devices must be stored and transported in anti-static bags. Fit new devices in a special handling area. For detailed information, refer to British Standard BS 5783 or other equivalent standard.

(2)

Open waveguides must be kept free of dirt and moisture by using plastic aperture seals when left unattended.

(3)

Use non-magnetic tools when working near the magnetron.

22

When a module is to be refitted, or a new one fitted, the refitting process is in the reverse order of the removal procedure unless otherwise stated.

Page 6.16

Issue 3

KH1207 Chapter 6 GAINING ACCESS TO THE TRANSCEIVER PCBS AND MODULES

23

The Transceiver Unit may be isolated in one of the following ways: (1)

Switching the Display or TIU OFF as appropriate.

(2)

Isolating the Display or TIU, as appropriate.

24

All setting up procedures are covered under ‘Checks after Unit Replacement’. After  replacement of any unit full functional checks are to be carried out.

25

To gain access to PCBs and Modules (refer to Figure 4): (1)

Remove the four captive screws securing the cover to the rear of the Transceiver  and remove cover.

(2)

Disconnect Plugs PLF, G, K, M and L from the Transceiver Terminals PCB.

(3)

Remove the four screws securing the RF Head to the Rotating Joint.

(4)

Remove the two bolts securing the Transceiver Electronics Module to the sliding rails.

(5)

The Transceiver Electronics Module may now be removed from the Transceiver.

 NOTE: When refitting any Module/PCB ensure that all Links/Switch positions are identical to that of the removed defective unit. The link/switches listed in the repair procedures are options for the installation and must be checked. All other links and switc hes are factory  set and are listed in the Unit Information in this manual. They should not require adjustment after repair. Whenever the end cover casting is removed for access to the units inside the transceiver, before replacement ensure the casting seal is clean and clear of obstacles. Check that all the screws are secure whilst the casting end cover is removed. Whenever the Transceiver Electronic Module is removed, inspect the input cable connections, look for worn seals/grommets, traces of water, loose connections and  strands of wire. LOCATION OF PCBS AND MODULES IN THE TRANSCEIVER 

26

The Transceiver contains the following PCBs and Modules, refer to Table 1. TABLE 1 - LOCATION OF PCBs AND MODULES PCB/Module

Identity

Refer to Figure

Modulator PCB Assembly

CTX-A332

5 and 8

Receiver PCB

CTX-A356

5 and 8

Transceiver Terminals PCB

CTX-A368

5 and 8

Azimuth PCB

CAE-A402/3

5 and 8

Magnetron Assembly

CTX-A197 (10kW)

5 and 8

Circulator Assembly

45-646-604

5 and 8

PIN Diode Driver & Limiter

CTX-A512

5 and 8

Low Noise Front End Assembly

CTX-A515

5 and 8

Issue 3

Page 6.17

KH1207 Chapter 6 27

The following options, refer to Table 2, are also available: TABLE 2 - LOCATION OF OPTIONAL PCBs AND MODULES PCB/Module

Identity

Refer to Figure…

Transmitter Monitor PCB

CTX-A198

4, 5 and 8

Sector Mute PCB (note that Nucleus and Manta displays can drive Sector Mute without CTX-A162 option)

CTX-A162

4 and 5

Receiver Monitor Cavity

CTX-A173

4

Monitor Arm

CAE-A147

4

REPLACING MODULES IN THE TRANSCEIVER  Removal of Transceiver Terminals PCB (CTX-A368)

28

To remove the Transceiver Terminals PCB proceed as follows: (1)

Isolate the Transceiver and gain access to the Transceiver Terminals PCB, as described in Paragraphs 23, 24 and 25(1) and 25(2) only.

(2)

If the Sector Mute PCB is fitted to the Transceiver Terminals PCB, remove the two fixings securing the Sector Mute PCB and pull the Sector Mute PCB off the Terminals PCB.

(3)

Disconnect Plugs PLA, C, D, E, and N.

(4)

Remove the three screws and two pillars securing the Transceiver Terminals PCB and remove the PCB from the Chassis.

Replacement of Transceiver Terminals PCB (CTX-A368)

29

To replace the Transceiver Terminals PCB, reverse the above procedure. Set the links as on the removed PCB. The links are: LK1 - A LK1 - B LK2 - MADE LK2 - OPEN

Antenna rotates on Run only Antenna rotates continuously Dummy sync pulse for Mute sector   No dummy sync for Mute sector  

Removal of Modulator PCB Assembly (CTX-A332)

30

To remove the Modulator PCB proceed as follows: (1)

Isolate the Transceiver and gain access to the Modulator PCB Assembly, as described in Paragraphs 23, 24 and 25.

(2)

Remove the Modulator cover by removing the cover retaining nut.

(3)

Disconnect Plugs PLA, PLB and the Green and Yellow power leads from the Magnetron.

Page 6.18

Issue 3

KH1207 Chapter 6 (4)

Remove the five screws and one pillar securing the Modulator PCB Assembly, refer to Figure 8, and remove the PCB from the Chassis.

Replacement of Modulator PCB Assembly (CTX-A332)

31

To replace the Modulator PCB Assembly, reverse the above procedure. Ensure the magnetron leads are supported without touching the chassis or the PCB components.

32

Set the modulator links to the same positions as on the unit removed. Other links are soldered onto the board to set current pulse width and should not be changed. The normal configuration of the links are:

LK1 LK2 LK3

Grid E1 F4 D4

LK4 LK5 LK6 LK7

D3 D3 C1

SW1

A7

 

Status MADE MADE OPEN

Function Heater current 400V HT connected to power output stage Automatic Magnetron Current control circuit enabled Not used OPEN Safety trips enabled MADE Trigger pulse jitter. Enabled MADE 75 ohm load connected allows modulator to run on its Internal trigger  ON

(Towards heatsink). HV supply enabled

Other links are soldered onto board to set current pulse width as follows: LK8, 9, 10 or 13 set Short Pulse width LK11, 12 or 14 set Medium Pulse width LK15 or 16 set Long Pulse Width Set up the modulator as detailed in 'Checks after Unit Replacement'. Removal of Receiver PCB (CTX-A356)

33

Issue 3

To remove the Receiver PCB proceed as follows: (1)

Isolate the Transceiver and gain access to the Receiver PCB, as described in Paragraphs 23, 24 and 25.

(2)

Disconnect Plugs PLA, C, D and E.

(3)

Remove the Receiver Assembly (CTX-A364) by removing the five retaining screws.

(4)

To remove the Receiver PCB from the Receiver Assembly, remove the eight  pillars securing the cover and PCB to the baseplate, and separate.

(5)

Note the positions of Links 1 to 9 if fitted.

Page 6.19

KH1207 Chapter 6 Replacement of Receiver PCB (CTX-A356)

34

To replace the Receiver PCB, reverse the above procedure. Set the links to the same  positions as on the unit removed. Do not adjust the potentiometer, as it is factory set. The normal configuration of the links are: LK1 LK2 LK3

LK4 LK5

LK6 LK7 LK8 LK9

As factory set Tune sample delay (intermediate, approx 50 ns) As factory set Tune sample delay (maximum, approx 100 ns) As factory set Tune sample delay (minimum) (Note: only one of LK1, LK2 or LK3 is to be MADE. Selected for best AFC performance) NOT FITTED B MADE Minimum AFC lock   A MADE Intermediate AFC lock   A & B MADE Maximum AFC lock  A MADE 2 bandwidths. SP & MP wideband, LP and VLP narrowband OPEN X band. Minimum Vco gain OPEN X band for +5 V supply MADE Sets regulator output to +5V

Removal of Azimuth PCB (CAE-A402/3)

35

To remove the Azimuth PCB proceed as follows: (1)

Isolate the Transceiver and gain access to the Azimuth PCB, as described in Paragraphs 23, 24 and 25.

(2)

Disconnect Plug PLA.

(3)

Note the position of pointer on scale, then remove the heading line adjustment locking screw.

(4)

Remove the nuts/locking nuts (4 off) and the nuts securing the Azimuth PCB and remove the PCB from the Chassis and Heading Line Adjustment Plate.

Replacement of Azimuth PCB (CAE-A402/3)

36

To replace the Azimuth PCB, reverse the above procedure and carry out the following: (1)

Set link to 90 position (90 azimuth pulses per revolution).

(2)

Ensure that when replacing the nuts/locking nuts (4 off) the PCB is held in place firmly, but able to be moved for Heading Line adjustment.

(3)

Adjust pointer to the position noted before the removal of the PCB. Fit adjustment locking screws.

(4)

The Heading Line will have to be checked/set up following replacement, refer to ‘Checks After Unit Replacement’.

Page 6.20

Issue 3

KH1207 Chapter 6 Removal of Magnetron Assembly (CTX-A197) CAUTION Use non-magnetic tools when working near the magnetron.

37

To remove the Magnetron Assembly proceed as follows: (1)

Isolate the Transceiver and gain access to the Magnetron Assembly, as described in Paragraphs 23, 24 and 25.

(2)

Disconnect the Green and Yellow leads from the Modulator PCB Assembly.

(3)

Remove the two screws securing the Magnetron Assembly and the two RF Head height adjustment screws, refer to Figure 8; remove the Magnetron Assembly from the RF Head.

Replacement of Magnetron Assembly (CTX-A197) CAUTION Use non-magnetic tools when working near the magnetron.

38

To replace the Magnetron Assembly, reverse the above procedure and then carry out the following: (1)

(2)

Align the RF Head and Rotating Joint, before tightening the Magnetron height adjustment screws as follows: (1)

Fit the chassis into the casting and fit the 4 waveguide screws.

(2)

Ensure that the chassis is correctly seated on the runners and tighten the Magnetron height adjustment screws that are accessible.

(3)

Remove the chassis, tighten the remaining adjustment screws.

(4)

Connect the magnetron leads, ensure they do not touch anything.

(5)

Fit the Modulator cover and then fit the chassis in the casting and reconnect the sockets.

Retune the Receiver Monitor Cavity (if fitted) as detailed in ‘Checks after Unit Replacement’.

 NOTE The Green lead has a larger terminal than the yellow lead.

Issue 3

Page 6.21

KH1207 Chapter 6 Removal of Circulator Assembly (45-646-604)

39

To remove the Circulator Assembly proceed as follows: (1)

Isolate the Transceiver and gain access to the Circulator Assembly, as described in Paragraphs 23, 24 and 25.

(2)

Remove the four Low Noise Front End and PIN Diode Driver/Limiter fixing screws (refer to Figure 8), the Magnetron fixing screws (refer to Figure 8) and the other two fixing screw securing the Magnetron Spacer to the Circulator  Assembly. Remove the Circulator Assembly from the RF Head.

Replacement of Circulator Assembly (45-646-604)

40

To replace the Circulator Assembly, reverse the above procedure and then carry out the following: (1)

Align the RF Head and Rotating Joint before tightening the Low Noise Front End (LNFE) and Magnetron height adjustment screws.

(2)

Tighten the Low Noise Front End (LNFE) and Magnetron height adjustment screws as follows: (1)

Fit the chassis into the casting and fit the four waveguide screws.

(2)

Ensure that the chassis is correctly seated on the runners and tighten the Magnetron and LNFE height adjustment screws that are accessible.

(3)

Remove the chassis, tighten the remaining adjustment screws.

(4)

Fit the Modulator cover and then fit the chassis in the casting and reconnect the sockets.

Removal of PIN Diode Driver and Limiter (CTX-A512)

41

To remove the PIN Diode Driver and Limiter proceed as follows: (1)

Isolate the Transceiver and gain access to the Diode Limiter, as described in Paragraphs 23, 24 and 25.

(2)

Disconnect PL1 from PIN Diode Driver PCB.

(3)

Note the orientation of the PIN Diode Driver and Limiter, by observing the arrow on the front of the unit.

(4)

Remove the four PIN Diode Driver and Limiter fixing screws, refer to Figure 8, and remove the PIN Diode Driver and Limiter from the RF Head.

(5)

Remove the unit. Note the orientation of the filter shim between the Limiter and the LNFE as this must be refitted the same way round.

Page 6.22

Issue 3

KH1207 Chapter 6 Replacement of PIN Diode Driver and Limiter (CTX-A512)

42

To replace the PIN Diode Driver and Limiter, reverse the above procedure, ensuring the unit is correctly oriented and the filter shim is fitted with the slot correctly oriented.

Removal of Low Noise Front End Assembly (CTX-A515)

43

To remove the LNFE Assembly proceed as follows: (1)

Isolate the Transceiver and gain access to the LNFE, as described in Paragraphs 23, 24 and 25.

(2)

Disconnect Sockets SKA, SKB and SKC from the LNFE.

(3)

Remove the six (LNFE) fixing screws, refer to Figure 8, and remove the LNFE from the RF Head.

Replacement of Low Noise Front End Assembly (CTX-A515)

44

Align the RF Head and Rotating Joint, before tightening the LNFE height adjustment screws as follows: (1)

Fit the chassis into the casting and fit the 4 waveguide screws.

(2)

Ensure that the chassis is correctly seated on the runners and tighten the LNFE height adjustment screws that are accessible.

(3)

Remove the chassis, tighten the remaining adjustment screws. Reconnect the sockets.

(4)

Fit the chassis in the casting.

Removal of Transmitter Monitor PCB (CTX-A198)

45

To remove the Transmitter Monitor PCB proceed as follows: (1)

Isolate the Transceiver and gain access to the Transmitter Monitor PCB, as described in Paragraphs 23, 24 and 25.

(2)

Disconnect Plug PLA.

(3)

Remove the four fixings securing the Transmitter Monitor PCB and remove the PCB from the Chassis.

Replacement of Transmitter Monitor PCB (CTX-A198)

46

Issue 3

To replace the Transmitter Monitor PCB, reverse the above procedure.

Page 6.23

KH1207 Chapter 6 Removal of Sector Mute PCB (CTX-A162)

47

To remove the Sector Mute PCB proceed as follows: (1)

Isolate the Transceiver and gain access to the Sector Mute PCB, as described in Paragraphs 23 and 24.

(2)

Remove the two screws securing the Sector Mute PCB and pull the PCB off the Transceiver Terminals PCB.

Replacement of Sector Mute PCB (CTX-A162)

48

To replace the Sector Mute PCB, reverse the above procedure. Set switches as for removed PCB.

Removal of Receiver Monitor Cavity (CTX-A173)

49

To remove the Receiver Monitor Cavity proceed as follows: (1)

Isolate the Transceiver and gain access to the Rx Monitor Cavity as described in Paragraphs 23, 24 and 25.

(2)

Disconnect cavity cable from the Terminals PCB PLL.

(3)

Lower the bottom part of the rotating joint by undoing the four retaining nuts which hold the joint in place. Do not move the four upper locating nuts.

(4)

Lower the rotating joint until the four bolts supporting the cavity can be removed.

(5)

Before removing the cavity, scribe a line by the cavity clamp plate so that the new unit can be correctly positioned if the alignment tool is not available.

Replacement of Receiver Monitor Cavity (CTX-A173)

50

To replace the cavity proceed as follows: (1)

Locate the cavity in position, lining up the hole in the waveguide and cavity using the alignment tool from inside the waveguide. If the tool i s not available, line up the clamp plate with the inscribed line.

(2)

Tighten the four screws evenly. Remove the alignment tool and replace the endplate (three screws) noting the position.

(3)

Replacement is then the reverse of the above procedure.

(4)

Tune the cavity after replacement, refer to ‘Checks after Unit Replacement’.

Page 6.24

Issue 3

KH1207 Chapter 6 Removal of Monitor Arm (CAE-A147)

51

To remove the Monitor Arm proceed as follows: (1)

Isolate the Transceiver and gain access to the Cable Gland, as described in Paragraphs 23, 24 and 25(1).

(2)

Disconnect the red core from Plug PLK pin 12 of the Transceiver Terminals PCB and the blue core from Plug PLK pin 13 of the Transceiver Terminals PCB.

(3)

Remove the Monitor Arm fixings and remove the Monitor Arm.

(4)

Remove the cable from the cable gland.

Replacement of Monitor Arm (CAE-A147)

52

To replace the Monitor Arm, reverse the above procedure and then carry out the following: (1)

Ensure that when fitting the Monitor Arm the orientation is correct, i.e. the alignment hole in the Monitor Arm mates with the alignment screw in the case.

(2)

Ensure that the reflecting surface on the Neon cover is facing away from the transceiver.

Removal of Motor (Low Speed (CAE-A30-20))

53

To remove the Motor proceed as follows: (1)

Isolate the Transceiver and gain access to the Antenna Motor as described in Paragraphs 23, 24 and 25.

(2)

Disconnect the motor supplies at the motor terminals.

(3)

Support the motor whilst undoing the two fixing nuts (through motor plate) located on each side of the motor.

(4)

Carefully lower the motor and remove from the housing.

Replacement of Motor (Low Speed (CAE-A30-20))

54

Issue 3

To replace the motor proceed as follows: (1)

Replace the motor, carefully meshing the pinion to the gears.

(2)

Support the motor and fasten the two fixing nuts removed in Paragraph 53 (3).

(3)

Reconnect the motor supplies.

Page 6.25

KH1207 Chapter 6 Removal of Motor (High Speed (CAE-A30-21))

55

To remove the Motor proceed as follows: (1)

Isolate the Transceiver and gain access to the Antenna Motor as described in Paragraphs 23, 24 and 25.

(2)

Disconnect the motor supplies at the Brushless Motor PCB, PL2 and PL3.

(3)

Support the motor whilst undoing the four fixing nuts (through motor plate) located at each corner of the plate.

(4)

Carefully lower the motor and remove from the housing.

Replacement of Motor (High Speed (CAE-A30-21))

56

To replace the motor proceed as follows: (1)

The centre sealing ring should be smeared with grease to allow it to locate smoothly, then fit in place.

(2)

Ensure that the anti-vibration rings are fitted over the fixing bolt shoulders.

(3)

Support the motor and fasten the four fixing nuts removed in Paragraph 55 (3).

(4)

Reconnect the motor supplies.

Removal of the Brushless Motor PCB (CAE-A236 (High Speed Motor))

57

To remove the Brushless Motor PCB proceed as follows: (1)

Isolate the transceiver and gain access to the Brushless Motor PCB as described in paragraphs 23, 24 and 25.

(2)

Disconnect PL1, PL2, PL3 and PL4.

(3)

Remove the three M4 screws located on the heat sink area and three pillars on the PCB area.

(4)

Remove the PCB.

Replacement of the Brushless Motor PCB (CAE-A236 (High Speed Motor))

58

To replace the Brushless Motor PCB reverse the above procedure.

Page 6.26

Issue 3

KH1207 Chapter 6 Removal of +26V Motor Starter Assembly (CTX-A359 (Low Speed Motor))

59

To remove the Motor Starter Assembly proceed as follows: (1)

Isolate the transceiver and gain access to the Starter Motor Assembly as described in paragraphs 23, 24 and 25.

(2)

Disconnect PLA and PLB and the motor leads.

(3)

Remove the two M4 screws located at the top corners and the two M4 pillars at the lower corners of the mounting plate.

(4)

Remove the assembly.

Replace ment of +26V Motor Starter Assembly (CTX-A359 (Low Speed Motor))

60

To replace the Motor Starter Assembly reverse the above procedure.

Removal of Rotating Joint

 NOTE If the removed Unit is to be reused ensure that the MOD level is at least MOD D (earlier units require factory setting up which cannot be accomplished in the field). 61

To remove the rotating joint: (1)

Issue 3

Remove the Antenna, as follows: (1)

Release the 4 waveguide nuts and bolts.

(2)

Releasing the 4 bolts, washers and nuts securing the antenna to the to the Turning Mechanism, and remove the antenna, ensuring that the waveguide seal is retained for reuse.

(2)

Gain access to the Starter Motor Assembly as described in paragraph 25.

(3)

Undo and retain the 3 screws that secure the top section of the rotating joint to the swing casting. Remove the top section.

(4)

Undo and retain the 4 nuts and washers holding the rotating joint securing plate onto the threaded pillars inside the gearbox.

(5)

Remove the lower section of the rotating joint taking care to retain the plain washers on top of the securing plate and the white plastic bush fitted into the driveshaft centre.

Page 6.27

KH1207 Chapter 6 Replacement of Rotating Joint

62

To replace the rotating joint: (1)

Ensure that the mating surfaces of the swing casting and the top section of the rotating joint are clean.

(2)

Apply a thin film of Hycomal Sealant on both surfaces.

(3)

Secure the top section to the swing casting using the 3 screws retained above.

(4)

Place the white plastic bush into the drive shaft centre hole.

(5)

Place the end of the rotating joint into the drive shaft through the bush.

(6)

Locate the 4 plain washers on top of the securing plate, align with the holes in the corner of the plate.

(7)

Slide the securing plate up the 4 threaded pillars to its fullest extent (ensure that the nuts on the threaded pillars do not prevent the rotating joint from sliding home).

(8)

Place 1 plain washer and nut on each threaded pillar and finger tighten to the rotating joint securing plate.

(9)

Run the top nut down and lock against the securing plate.

(10)

Replace the antenna as follows:

Page 6.28

(1)

Ensure the waveguide faces are clean and free from grease. Loosely attach the antenna to the swing casting using the 4, M8 x 75 mm bolts, washers and nyloc nuts. Apply Loctite to all screws.

(2)

Connect the antenna waveguide to the turning mechanism's rotating joint using the 'O' ring and nuts, washers and bolts.

(3)

Waterproof the waveguide joint by sealing with a layer of greased plastic compound such as Henleys compound or Denso-Tape.

(4)

Tighten fasteners holding swing casting to antenna to a torque of 29 Nm.

Issue 3

KH1207 Chapter 6 CHECKS AFTER UNIT REPLACEMENT

63

Any maintenance, or rectification, involving the replacement of PCBs or Modules within the Transceiver involves certain procedures to bring the Display up to full working order. The majority of PCBs and Modules have been factory tested, and preset , and do not require any adjustment. However, certain equipments are of non-standard fit and therefore require setting up checks to enable the set to become operational. 64

The following paragraphs and sub-paragraphs are procedures that the maintainer or  installer must follow to gain satisfactory performance of the equipment. WARNING

DURING THESE PROCEDURES THE ANTENNA IS REQUIRED TO BE ROTATING, CARE IS TO BE TAKEN IF CHECKS ARE TO BE MADE AT THE TRANSCEIVER. Modulator PCB

65

For systems fitted with a TIU only, the heater current must be measured and links adjusted as required. For other systems there are no adjustments required. To do this carry out the following (refer to Figure 9): (1)

Issue 3

Set the TIU power supply switches: SW1

SW2

CAE-A30-20

ON (9.9V)

ON (26V)

Low speed

CAE-A30-21

ON (9.9V)

OFF (36V)

High speed

(2)

To measure the heater current connect an ammeter in series with wire from the TIU Terminals PCB (NNR-A1004) pin 3.

(3)

Switch the system ON. KEEP AT STANDBY ONLY. DO NOT SWITCH TO RUN.

(4)

The Heater Current is to be between 0.56A and 0.6A.

(5)

If it is low, Switch system OFF, and short out R1 on TIU Terminals PCB (NNR-A1004) (either solder a wire link across R1 or set LK1 to position A if  there is one).

(6)

Switch the system ON.

(7)

If the current is still low, switch the system OFF and make link LK1 on the Transmitter Modulator PCB (CTX-A332).

(8)

Switch the system ON. Once the heater current is correct, switch the system OFF.

Page 6.29

KH1207 Chapter 6 Transceiver Terminals PCB

66

There are no checks for this PCB other than ensuring that the links and switches are set as on the removed PCB.

Azimuth PCB

67

Following replacement of the Azimuth PCB, check/set up the heading line to give maximum bearing accuracy, as follows: (1)

During the Heading Line alignment procedure, the ship must be stationary or at anchor on a fixed known heading and must have bearing information from the gyro compass available. The ship is to be alongside; less accurate results are obtained if at anchor or at a buoy.

(2)

Check that the array/gearbox alignment mark /\ is correct.

(3)

Switch ON the Display and operate in a HEAD UP mode and a range of 6 miles.

(4)

If possible, observe a target directly ahead of the ship. The target is to be directly under the heading line. Note any bearing error between the target and heading line. Alternatively, select a stationary target which can be seen by eye and which  paints an echo on the screen. Take a compass bearing on the target, and compare this with the bearing of the echo paint on the display. Note the degree and direction of discrepancy.

(5)

The display 'INSTALLATION MENU' Skew setting is to be adjusted to correct the error.

Magnetron Assembly

68

Following the replacement of the Magnetron Assembly retune the Receiver Monitor  Cavity, as follows:

 NOTE A two way communication link is to be available, between the Transceiver and  Display, for setting up the Receiver Monitor Cavity. (1)

Ensure that the Display Tune control is adjusted to obtain the maximum indication (length) of the Tune ribbon at the top of the screen.

(2)

Switch the Display to OFF.

(3)

Switch the Transceiver Isolator switch to OFF.

(4)

Remove the four captive screws securing the cover to the front of the Transceiver  and remove cover.

(5)

Slacken off the Receiver Monitor Cavity Adjuster Locking Screw.

Page 6.30

Issue 3

KH1207 Chapter 6 WARNING SETTING UP OF THE RECEIVER MONITOR CAVITY HAS TO BE DONE WITH THE SYSTEM OPERATIVE. BEFORE SETTING THE ISOLATOR  SWITCH TO ON ENSURE ALL PERSONNEL ARE CLEAR OF THE ROTATING ANTENNA. CARE IS ALSO TO BE TAKEN WHEN SETTING THE RECEIVER  MONITOR CAVITY ADJUSTER AS THE CIRCUITS ARE LIVE.

(6)

Switch the Display to ON.

(7)

Switch the Transceiver Isolator switch to ON.

(8)

Go to RUN and adjust the TUNE control for maximum peak indication on LP. Activate the Performance Monitor.

(9)

Adjust Receiver Monitor Cavity Adjuster for the maximum diameter ‘sun’ on the radar screen (3nm range).

(10)

Tighten the Receiver Monitor Cavity Adjuster Locking Screw and secure the Transceiver cover.

(11)

The range of the ‘sun’ is to be measured, refer to Figure 10, using the VRM and recorded in the equipment log book.

(12)

Switch to the 12nm range and record the length of the Tx Monitor ‘Plume’.

Low Noise Front End

69

Check that the Display picture can be correctly tuned on all ranges.

Diode Limiter

70

Check that the Display picture can be correctly tuned on all ranges.

Receiver Monitor Cavity

71

Issue 3

Check that the Display picture can be correctly tuned on all ranges.

Page 6.31

KH1207 Chapter 6

INTENTIONALLY BLANK 

Page 6.32

Issue 3

KH1207 Chapter 6

WARNING SWITCH OFF AT SAFETY SWITCH

Tx MONITOR ARM (OPTIONAL)

NOTE: WHEN REFITTING UNIT DO NOT DAMAGE MATING FACES OF WAVEGUIDE Rx MONITOR CAVITY CTX-A173 (OPTIONAL)

AZIMUTH PCB CAE-A402-3 AZIMUTH PCB LOCKING SCREW & CALIBRATION GUIDE

M4 CIRCULATOR RETAINING SCREWS (CAPTIVE) RECEIVER ASSEMBLY CTX-A364 (ON SIDE)

MOTOR STARTER PCB CTX-A359 or MOTOR DRIVE PCB CAE-A236 (AT BACK OF CASTING)

STATIC STUD

SAFETY SWITCH LOCATED ON UNDERSIDE OF CASTING TERMINALS PCB CTX-A368

DISCONNECT ELECTRICAL PLUGS MODULATOR PCB CTX-A332 & MAGNETRON CTX-A197 (BENEATH COVER)

M5 CHASSIS RETAINING BOLTS

TRANSCEIVER UNIT SHOWN WITH FRONT COVER REMOVED

Tx MONITOR PCB CTX-A198 (UNDERNEATH) ANTENNA MOTOR TERMINAL BLOCK TB2

CD-3737

ISSUE 2

Figure 4 - Transceiver Electronics Module: Access

Issue 3

Page 6.33

KH1207 Chapter 6

PIN DIODE DRIVER & LIMITER CTX-A512 LNFE WITH SHIM FILTER BETWEEN THE LNFE & THE PIN DIODE DRIVER & LIMITER

AZIMUTH PCB CAE-A402-3

CIRCULATOR RETAINING SCREWS

PIN DIODE DRIVER PCB

CIRCULATOR ASSEMBLY 45-646-604 RF FILTER

Rx MONITOR CAVITY CTX-A173 SECTOR MUTE PCB CTX-A162 (OPTIONAL)

   W    k    3    1

MODULATOR PCB COVER

   R   E    E   G    A    T    G   L    O    N   V    G    A   H    I    D   H

Tx MONITOR PCB (OPTION) UNDER CHASSIS

CD-3835

TRANSCEIVER TERMINALS PCB CTX-A368 CHASSIS RETAINING SCREWS TB2

ISSUE 2

Figure 5 - Transceiver Electronics Module

Page 6.34

Issue 3

KH1207 Chapter 6

FILTER

MOTOR

MOTOR STARTER PCB

CD-3843

Figure 6 - Location of Motor Starter PCB (CAE-A30-20 only)

Issue 3

Page 6.35

KH1207 Chapter 6

BRUSHLESS DC MOTOR

PL3         2         L         P         4         L         P

   D    R    A    Z    A    H    E    V    A     W    O  I    D    A    R    m   2    N    A    H    T    S    S    E   L    T    A         1         L         P

   R    E    G    N    A    D

BRUSHLESS MOTOR PCB

CD-3606

ISSUE 2

Figure 7 - Location of Brushless Motor PCB (CAE-A30-21 only)

Page 6.36

Issue 3

KH1207 Chapter 6

CABLE CTX-A513

MODULATOR PCB ASSEMBLY CTX-A332

CABLE CTX-A367

P  L   B 

PLE

PLA

CABLE CTX-A410

PLD

AZIMUTH PCB CAE-A402-3

PLA

CABLE CTX-A321

SKA

CIRCULATOR 45-646-604

P1 Y

P2 GN

P  L   A 

MAGNETRON LEADS TO BE TWISTED TOGETHER THEN COOLED TWICE BEFORE FITTING IN THE STAND OFF CLIP. THE LEADS ARE THEN CONNECTED TO THE PCB. THE COILS ARE TO BE KEPTAWAYFROM THE PCB AND MUSTNOTTOUCH ANYMETALWORK, INCLUDING THE COVER WHEN FITTED

LOGARITHMIC RECEIVER CTX A364 LOW NOISE FRONTEND CTX-A315

EARTH BRAID TO BE SECURED TO MAGNETRON AS SHOWN MAGNETRON CTX-A197

    3

   1

    2

CABLE CTX-A366

 .   o  .    N   o    E    N  .    D    R    O    E    C    S

PLN

CABLE CTX-A168

TRANSMITTER MONITOR PCB CTX-A198

SMB CONNECTORS RF HEAD HEIGHTADJUS TMENTSCREWS

BASE VIEW

LOW NOISE FRONTEND DIODE LIMITER FIXING SCREWS

HEADING LINE ADJUSTMENT LOCKING SCREW

PIN DIODE DRIVER & LIMITER TERMINALS PCB FILTER CTX-A512 CTX-A368 45-750-0215-001

SIDE VIEW (MODULATOR COVER REMOVED)

TOP VIEW

SIDE VIEW (RECEIVER COVER REMOVED) PIN DIODE DRIVER & LIMITER CTX-A512

FILTER 45-750-0015-001

   W    k    3    1 PLA

LNFE CTX-A515

WAVEGUIDE SHIM NTX-1194

PIN DIODE DRIVER & LIMITER CTX-A512 PLE

PLC

PLD

   C   F    K   /    S   I

FILTER 45-750-0015-001

TERMINALS PCB CTX-A368

   B    E    K    N    S    U    T

   E

   G    R    E   A    T    L    G    O    V    N    A   H    G    I    D    H

   A   V    K    S   5   +

MAGNETRON CTX-A197

FRONT VIEW SCRAP VIEW SHOWING POSITIONING OF WAVEGUIDE SHIM NTX-1194 BETWEEN LNFE CTX-A515 & PIN DIODE DRIVER/LIMITER CTX-A512

Figure 8

Issue 3

SCRAP VIEW SHOWING POSITIONING OF FILTER NJC9937 45-750-0015-001 (RECEIVER COVER REMOVED)

CD-6902

Assembly of Transceiver: Component Location

Figure 8

Page 6.37/38

KH1207 Chapter Chap ter 6

TRANSMITTER INTERFACE UNIT NNR-A66

Mk 5 TRANSCEIVER CAE-A30-7, -8, -20, -21 TERMINALS PCB CTX-A368

TERMINALS PCB NNR-A1004

POWER SUPPLY UNIT 45-677-124

A +9.9V ±0.4V 0V

1R0

LK1

MODULATOR PCB CTX-A332 (NORMALLY OPEN)

LK1

B PLB-3 PLB-4

2

A

+ve WIRE V DROP (0.5mm ) 22.6mV/METRE @ 0.58A -ve WIRE V D ROP ROP,, VERY LOW DUE TO MULTI-P MULTI-PATH ATH CONNECTIONS

+V PLG-1

1R0

0V PLG-2 FILTER INDUCTOR

PULSE TRANSFORMER (1R5) 5.7V to 6.9V Gn Y

MAGNETRON

5.7V to 6.9V PULSE TRANSFORMER (1R5)

HEATER SENSE (0R33)

CD-6943

ISSUE 1

Figure 9 - MkV with TIU: System Heater Circuit

KH1207 Chapter Chap ter 6

TRANSMITTER INTERFACE UNIT NNR-A66

Mk 5 TRANSCEIVER CAE-A30-7, -8, -20, -21 TERMINALS PCB CTX-A368

TERMINALS PCB NNR-A1004

POWER SUPPLY UNIT 45-677-124

A +9.9V ±0.4V 0V

1R0

LK1

MODULATOR PCB CTX-A332 (NORMALLY OPEN)

LK1

B PLB-3 PLB-4

2

A

+ve WIRE V DROP (0.5mm ) 22.6mV/METRE @ 0.58A -ve WIRE V D ROP ROP,, VERY LOW DUE TO MULTI-P MULTI-PATH ATH CONNECTIONS

+V PLG-1

1R0

0V PLG-2 FILTER INDUCTOR

PULSE TRANSFORMER (1R5) 5.7V to 6.9V Gn Y

MAGNETRON

5.7V to 6.9V PULSE TRANSFORMER (1R5)

HEATER SENSE (0R33)

CD-6943

ISSUE 1

Figure 9 - MkV with TIU: System Heater Circuit

Isssue 3 Is

Page 6.39

KH1207 Chapter 6 010

350

020

340 330

030

320

040

310

050

300

060

070

290

080

280

090

270

260

100

250

110

240

120

130

230

140

220 210

150 200

CD-7555

160 190

ISSUE 1

180

170

Receiver Monitor 350

000

010 020

340 330

030

320

040

310

050

300

060

070

290

080

280

090

270

260

100

250

110

240

120

130

230

140

220 210

150 200

CD-7557

ISSUE 1

160 190

180

170

Transmitter Monitor

Figure 10 - Performance Monitor Display

Page 6.40

Issue 3

KH1207 Chapter Chap ter 7

CHAPTER 7

PARTS LIST CONTENTS CON TENTS Paragraph

1

Page

INTRO TRODUC DUCT TION

7.3

PARTS LISTS Parts List

PL1 PL2 PL3 PL4 PL5

Page

Transceiver/Turning Mechanism: CAE-A30-20 Transceiver/Turning Mechanism: CAE-A30-21 Assembly of Gearbox: CAE-A280 (Low Speed) Assembly of Gearbox: CAE-A245 (High Speed) Assembly of Transceiver: CTX-A363 (10kW)

7.5 7.5 7.7 7.8 7.11

ILLUS IL LUSTRA TRATIONS TIONS Figure

1 2 3

Isssue 3 Is

Page

Transceiver/Turning Mechanism: Main Assemblies Assembly of Gearbox: Component Location Assembly of Transceiver: Component Location

7. 7.6 7.10

Page 7.1

KH1207 Chapter 7

THIS PAGE INTENTIONALLY BLANK 

Page 7.2

Issue 3

KH1207 Chapter 7

CHAPTER 7

PARTS LIST INTRODUCTION

1

This Chapter provide Parts List and drawings, showing layout and location information, to support the two versions of MkV X-band Upmast Transceivers.

2

The Parts Lists are presented in tabular form and provide a description and Kelvin Hughes part number for each item labelled on the associated drawing. Items are cross referenced to the parts list by a number.

Issue 3

Page 7.3

KH1207 Chapter 7

RECEIVER MONITOR CAVITY CTX-A173

ASSY OF TRANSCEIVER CTX-A363

   V    k    3    1

   R   E    G    E   A    T    G   L    O    N   V    H    A   G    I    D   H PLL

PLM

ASSY OF CABLEFORM CAE-A283

CD-6883

Figure 1 - Transceiver/Turning Mechanism: Main Assemblies

Page 7.4

Issue 3

KH1207 Chapter 7 PL1 - Transceiver/Turning Mechanism: CAE-A30-20 CIRCUIT REF.

GRID REF.

DESCRIPTION

KELVIN HUGHES PART No.

ASSY. OF GEARBOX

CAE-A280

ASSY. OF CABLE FORM 2SKM-SWITCH

CAE-A283

ASSY. OF TRANSCEIVER (10kW)

CTX-A363

FITTING KIT

CTX-A170

PERFORMANCE MONITORING KIT (OPTIONAL), comprising:

CTX-A171

Tx Monitor Arm

CAE-A147

Rx Monitor Cavity

CTX-A173

Rx Monitor PCB

CTX-A198

Cableform 2SKN-7SKA

CTX-A168

PL2 - Transceiver/Turning Mechanism: CAE-A30-21 CIRCUIT REF.

Issue 3

GRID REF.

DESCRIPTION

KELVIN HUGHES PART No.

ASSY. OF GEARBOX

CAE-A245

ASSY. OF CABLE FORM 2SKM-SWITCH

CAE-A261

ASSY. OF TRANSCEIVER (10kW)

CTX-A363

FITTING KIT

CTX-A170

PERFORMANCE MONITORING KIT (OPTIONAL), comprising:

CTX-A171

Tx Monitor Arm

CAE-A147

Rx Monitor Cavity

CTX-A173

Rx Monitor PCB

CTX-A198

Cableform 2SKN-7SKA

CTX-A168

Page 7.5

KH1207 Chapter 7

     N      Y      O       T      M      I      V      X      A      R      C 

     2      2      7      3  -       D      C 

Figure 2 - Assembly of Gearbox: Component Location

Page 7.6

Issue 3

KH1207 Chapter 7 PL3 - Assembly of Gearbox: CAE-A280 (Low Speed) ITEM No.

DESCRIPTION

KELVIN HUGHES PART No.

1

CASTING

CAE-A229

2

BEARING 35 x 62 x 14mm WITH SHIELDS TYPE 6007-2Z R.H.P.

45-173-1548

3

SHIM BEARING

CAE-4028/1

SHIM BEARING

CAE-4028/2

SHIM BEARING

CAE-4028/3

4

MAIN GEAR AND SHAFT

CAE-4063

5

WING CASTING (CAE-1018 MODIFIED)

CAE-4029

6

‘V’ SEAL TYPE VA 0095 HEADLAND

35-781-739

7

BEARING 50 x 80 x 16mm WITH SHIELDS TYPE 6010-2Z R.H.P.

45-173-1545

8

DRIVE SHAFT

CAE-4012

9

GEAR PLATE

CAE- 4004

10

BEARING 12 x 28 x 8mm WITH SHIELDS TYPE 6001-2Z R.H.P.

45-173-1549

11

GEARWHEEL & PINION 2nd STAGE

CAE-1415

12

GEARWHEEL & PINION 1st STAGE (106T)

CAE-1605

13

PINION MOTOR (20T)

CAE-1280

14

SPIROL PIN 2.5 DIA x 16 LG TYPE MDP

20-287-4542-49

15

DISC CARRIER

CAE-4006

16

DISC OPTICAL

CAE-4005

17

+26V MOTOR START PCB

CTX-A359

18

DC MOTOR (LOW SPEED)

CAE-A281

19

CASE CASTING

CAE-4002

25KW ROTATING JOINT

CAE-A415

ASSEMBLY OF CABLEFORM

CAE-A283

RUNNER L.H.

CAE-4014

RUNNER R.H.

CAE-4015

ASSY. OF RESTRAINT CORD

CAE-A119

SPECIAL WASHER

CAE-1110

CLIP

CAE-4016

BOLT SPECIAL

CAE-4017

SPACER

CAE-4030

 NUT SPECIAL

CAE-1625

 NEOPRENE CORD ¼” DIA. BAINES

5662-202

SPIROL PIN 2.0 DIA x 12 LG SPIROL TYPE MCS STD. DUTY STST CAD PL.

25-287-001

CABLE GLAND BRASS No. 248-S

85-267-872

CABLE GLAND BRASS No. 254

85-267-874

Issue 3

Page 7.7

KH1207 Chapter 7 PL4 - Assembly of Gearbox: CAE-A245 (High Speed) ITEM No.

DESCRIPTION

KELVIN HUGHES PART No.

1

CASTING

CAE-A229

2

BEARING 35 x 62 x 14mm WITH SHIELDS TYPE 6007-2Z R.H.P.

45-173-1548

3

SHIM BEARING

CAE-4028/1

SHIM BEARING

CAE-4028/2

SHIM BEARING

CAE-4028/3

4

MAIN GEAR AND SHAFT

CAE-4063

5

WING CASTING (CAE-1018 MODIFIED)

CAE-4029

6

‘V’ SEAL TYPE VA 0095 HEADLAND

35-781-739

7

BEARING 50 x 80 x 16mm WITH SHIELDS TYPE 6010-2Z R.H.P.

45-173-1545

8

DRIVE SHAFT

CAE-4012

9

GEAR PLATE

CAE- 4004

10

BEARING 12 x 28 x 8mm WITH SHIELDS TYPE 6001-2Z R.H.P.

45-173-1549

11

GEARWHEEL & PINION 2nd STAGE

CAE-1415

12

GEARWHEEL & PINION 1st STAGE (106T)

CAE-1414

13

PINION MOTOR (20T)

CAE-1280

14

SPIROL PIN 2.5 DIA x 16 LG TYPE MDP

20-287-4542-49

15

DISC CARRIER

CAE-4006

16

DISC OPTICAL

CAE-4005

17

BRUSHLESS MOTOR PCB

CAE-A236

18

ASSEMBLY OF MOTOR BRUSHLESS (PAPST)

CAE-A246

19

CASE CASTING

CAE-4002

25KW ROTATING JOINT

CAE-A415

ASSEMBLY OF CABLEFORM

CAE-A261

MOTOR MOUNT

CAE-1622

RUNNER L.H.

CAE-4014

RUNNER R.H.

CAE-4015

ASSY. OF RESTRAINT CORD

CAE-A119

SPECIAL WASHER

CAE-1110

CLIP

CAE-4016

BOLT SPECIAL

CAE-4017

SPACER

CAE-4030

 NUT SPECIAL

CAE-1625

 NEOPRENE CORD ¼” DIA. BAINES

5662-202

SPIROL PIN 2.0 DIA x 12 LG SPIROL TYPE MCS STD. DUTY STST CAD PL.

25-287-001

CABLE GLAND BRASS No. 248-S

85-267-872

CABLE GLAND BRASS No. 254

85-267-874

Page 7.8

Issue 3

KH1207 Chapter 7

THIS PAGE INTENTIONALLY BLANK 

Issue 3

Page 7.9

KH1207 Chapter 7

CABLE CTX-A513

MODULATOR PCB ASSEMBLY CTX-A332

CABLE CTX-A367

P  L   B 

PLE

PLA

CABLE CTX-A410

PLD

AZIMUTH PCB CAE-A402-3

PLA

CABLE CTX-A321

SKA

CIRCULATOR 45-646-604

P1 Y

P2 GN

P  L   A 

MAGNETRON LEADS TO BE TWISTED TOGETHER THEN COOLED TWICE BEFORE FITTING IN THE STAND OFF CLIP. THE LEADS ARE THEN CONNECTED TO THE PCB. THE COILS ARE TO BE KEPTAWAYFROM THE PCB AND MUSTNOTTOUCH ANYMETALWORK, INCLUDING THE COVER WHEN FITTED

LOGARITHMIC RECEIVER CTX A364 LOW NOISE FRONTEND CTX-A315

EARTH BRAID TO BE SECURED TO MAGNETRON AS SHOWN MAGNETRON CTX-A197

    3

   1

    2

CABLE CTX-A366

 .   o  .    N   o    E    N  .    D    R    O    E    C    S

PLN

CABLE CTX-A168

TRANSMITTER MONITOR PCB CTX-A198

SMB CONNECTORS RF HEAD HEIGHTADJUS TMENTSCREWS

BASE VIEW

LOW NOISE FRONTEND DIODE LIMITER FIXING SCREWS

HEADING LINE ADJUSTMENT LOCKING SCREW

PIN DIODE DRIVER & LIMITER TERMINALS PCB FILTER CTX-A512 CTX-A368 45-750-0215-001

SIDE VIEW (MODULATOR COVER REMOVED)

TOP VIEW

SIDE VIEW (RECEIVER COVER REMOVED) PIN DIODE DRIVER & LIMITER CTX-A512

FILTER 45-750-0015-001

   W    k    3    1 PLA

LNFE CTX-A515

WAVEGUIDE SHIM NTX-1194

PIN DIODE DRIVER & LIMITER CTX-A512 PLE

PLC

PLD

   C   F    K   /    S   I

FILTER 45-750-0015-001

TERMINALS PCB CTX-A368

   B    E    K    N    S    U    T

   E

   G    R    E   A    T    L    G    O    V    N    A   H    G    I    D    H

   A    K   V    S   5   +

MAGNETRON CTX-A197

FRONT VIEW SCRAP VIEW SHOWING POSITIONING OF WAVEGUIDE SHIM NTX-1194 BETWEEN LNFE CTX-A515 & PIN DIODE DRIVER/LIMITER CTX-A512

Figure 3

Page 7.10

SCRAP VIEW SHOWING POSITIONING OF FILTER NJC9937 45-750-0015-001 (RECEIVER COVER REMOVED)

CD-6902

Assembly of Transceiver: Component Location

Figure 3

Issue 3

KH1207 Chapter 7

CABLE CTX-A513

MODULATOR PCB ASSEMBLY CTX-A332

CABLE CTX-A367

P  L   B 

PLE

PLA

CABLE CTX-A410

PLD

AZIMUTH PCB CAE-A402-3

PLA

CIRCULATOR 45-646-604

CABLE CTX-A321

SKA

P1 Y

P2 GN

P  L   A 

MAGNETRON LEADS TO BE TWISTED TOGETHER THEN COOLED TWICE BEFORE FITTING IN THE STAND OFF CLIP. THE LEADS ARE THEN CONNECTED TO THE PCB. THE COILS ARE TO BE KEPTAWAYFROM THE PCB AND MUSTNOTTOUCH ANYMETALWORK, INCLUDING THE COVER WHEN FITTED

LOGARITHMIC RECEIVER CTX A364 LOW NOISE FRONTEND CTX-A315

EARTH BRAID TO BE SECURED TO MAGNETRON AS SHOWN MAGNETRON CTX-A197

    3

   1

    2

CABLE CTX-A366

 .   o  .    N   o    E    N  .    D    R    O    E    C    S

PLN

CABLE CTX-A168

TRANSMITTER MONITOR PCB CTX-A198

SMB CONNECTORS RF HEAD HEIGHTADJUS TMENTSCREWS

BASE VIEW

LOW NOISE FRONTEND DIODE LIMITER FIXING SCREWS

HEADING LINE ADJUSTMENT LOCKING SCREW

PIN DIODE DRIVER & LIMITER TERMINALS PCB FILTER CTX-A512 CTX-A368 45-750-0215-001

SIDE VIEW (MODULATOR COVER REMOVED)

TOP VIEW

SIDE VIEW (RECEIVER COVER REMOVED) PIN DIODE DRIVER & LIMITER CTX-A512

FILTER 45-750-0015-001

   W    k    3    1 PLA

LNFE CTX-A515

WAVEGUIDE SHIM NTX-1194

PIN DIODE DRIVER & LIMITER CTX-A512 PLE

PLC

PLD

FILTER 45-750-0015-001

   C   F    K   /    S   I

TERMINALS PCB CTX-A368

   B    E    K    N    S    U    T

   E

   G    R    E   A    T    L    G    O    V    N    A   H    G    I    D    H

   A   V    K    S   5   +

MAGNETRON CTX-A197

FRONT VIEW SCRAP VIEW SHOWING POSITIONING OF WAVEGUIDE SHIM NTX-1194 BETWEEN LNFE CTX-A515 & PIN DIODE DRIVER/LIMITER CTX-A512

SCRAP VIEW SHOWING POSITIONING OF FILTER NJC9937 45-750-0015-001 (RECEIVER COVER REMOVED)

Figure 3

CD-6902

Assembly of Transceiver: Component Location

Figure 3

Page 7.10

Issue 3

KH1207 Chapter 7 PL5 - Assembly of Transceiver: CTX-A363 (10kW) ITEM GRID No. REF.

DESCRIPTION

KELVIN HUGHES PART No.

ASSY. OF AZIMUTH PCB

CAE-A402/3

ASSY. OF MODULATOR PCB

CTX-AA332

ASSY OF RECEIVER, INCLUDING:

CTX-A364

ASSY. OF RECEIVER PCB

CTX-C356

ASSY. OF TERMINALS PCB

CTX-A368

ASSY. OF SECTOR MUTE PCB (OPTION)

CTX-A162

DET’D ASSY. OF MOUNT PCB

CTX-A405

LOWPASS FILTER X-BAND

45-750-0015-001

ASSY. OF LOW NOISE FRONT END

CTX-A515

ASSY. OF MAGNETRON (10 kW)

CTX-A197

X-BAND FILTER

45-750-0015-001

CABLEFORM

CTX-A168

CABLEFORM

CTX-A365

CABLEFORM

CTX-A366

CABLEFORM

CTX-A367

CABLEFORM

CTX-A410

CABLEFORM

CTX-A513

WAVEGUIDE SHIM

NTX-1194

PILLAR RECEIVER

CTX 1025

KH1207 Chapter 7 PL5 - Assembly of Transceiver: CTX-A363 (10kW) ITEM GRID No. REF.

DESCRIPTION ASSY. OF AZIMUTH PCB

CAE-A402/3

ASSY. OF MODULATOR PCB

CTX-AA332

ASSY OF RECEIVER, INCLUDING:

CTX-A364

ASSY. OF RECEIVER PCB

CTX-C356

ASSY. OF TERMINALS PCB

CTX-A368

ASSY. OF SECTOR MUTE PCB (OPTION)

CTX-A162

DET’D ASSY. OF MOUNT PCB

CTX-A405

LOWPASS FILTER X-BAND

45-750-0015-001

ASSY. OF LOW NOISE FRONT END

CTX-A515

ASSY. OF MAGNETRON (10 kW)

CTX-A197

X-BAND FILTER

45-750-0015-001

CABLEFORM

CTX-A168

CABLEFORM

CTX-A365

CABLEFORM

CTX-A366

CABLEFORM

CTX-A367

CABLEFORM

CTX-A410

CABLEFORM

CTX-A513

WAVEGUIDE SHIM

NTX-1194

PILLAR RECEIVER

CTX-1025

COVER MODULATOR

CTX-4006

PANEL L.H.

CTX-4007

PANEL R.H.

CTX-4008

SPACER W/G

CTX-4012

PLATE LOCKING

CTX-4019

CIRCULATOR TYPE NJC 3901B

Issue 3

KELVIN HUGHES PART No.

NJRC

45-646-604

PIN DIODE DRIVER AND LIMITER

CTX-A512

FILTER SHIM

NTX-1194

TRANSMITTER MONITOR PCB

CTX-A198

Page 7.11

KH1207 Chapter 7

THIS PAGE INTENTIONALLY BLANK 

Page 7.12

Issue 3

KH1207 Annex A

ANNEX A

LONG CABLE RUNS AND INLINE POWER SUPPLY CONTENTS

Paragraph

1 3

5 6

Page

INTRODUCTION INSTALLATION CABLE SPECIFICATIONS Co-axial Ca ble 75 ohms low loss (for extended ca ble runs) WIRING DIAGRAMS SETTING UP PROCEDURE FOR LINE AMPLIFIERS RAN-A26 AND RAN-A27-2

A.3 A.3 A.3 A.3 A.3 A.7

ILLUSTRATIONS Figure

1 2 3 4

Issue 3

Page

Line Head Amplifier (RAN-A26) & Line Receiver (RAN-A27-2): Installation Dimensions Line Amplifier/In Line PSU (HRC-A28-1): Installation Dimensions Upmast Transceiver (CAE-A30-20, CAE-A30-21) with Long Cables using CAN Bus Interface: Typical Interconnections Effect of Compensation Capacitors on Output Waveforms

A.4 A.5 A.6 A.8

Page A.1

KH1207 Annex A

THIS PAGE INTENTIONALLY BLANK 

Page A.2

Issue 3

KH1207 Annex A

ANNEX A

LONG CABLE RUNS AND INLINE POWER SUPPLY INTRODUCTION

1

Where the total distance between the transceiver and the display is between 65 and 180 metres, the co-axial cables in the 14 Core or 38 Core cable ar e to be replaced by Low Loss Co-axial cables. Where the distance is greater than 180 metres, the Low Loss cable must be used with the Head and Line Receiver Units. The Receiver shall be sited as close as possible to the display or interswitch unit. 2

The Inline Power Supply (HRC-A28-1) provides the DC supplies to the Transceiver and contains the Line Head Amplifier (RAN-A26). If the Inline Power Supply is not r equired (when a TIU is used), the Line Head Amplifier (RAN-A26) is supplied as a separate item. The Line Receiver (RAN-A27-2) is always a separate item. INSTALLATION

3

With reference to Figure 1, secure the Line Head Amplifier (RAN-A26) or Line Receiver (RAN-A27-2) in the required position (no fittings are supplied).

4

With reference to Figure 2, secure the Inline Power Supply (HRC-A28-1) in the required  position (no fittings are supplied).

CABLE SPECIFICATIONS Co-axial Cable 75 ohms low loss (for extended cable runs)

Coaxial Cable: Inner conductor: Dielectric: Screen: Overall Dia:

CODE number 5344-719 Type ECL 125 (Manufacturer’s code) 1.25 mm Single Conductor   Air spaced Polyethylene Tape Screen 8.3 mm

Electrical Attenuation: Impedance:

60 MHz 3.4 dB/100m MAX 100 MHz 4.9 dB/100m MAX 75 Ohm

WIRING DIAGRAMS

5

Figures 3 and 4 detail typical electrical connections between the display and the Transceiver which is to be used with in-line power supply (used where cable runs of  greater than 180 metres are required).

Issue 3

Page A.3

KH1207 Annex A

VIDEO IN

DC SUPPLY

SYNC IN

   0    2    1

VIDEO OUT

SYNC OUT

   0    6

204

   2    8

Ø 5mm

CD-1158

Figure 1 - Line Head Amplifier (RAN-A26) & Line Receiver (RAN-A27-2): Installation Dimensions

Page A.4

Issue 3

KH1207 Annex A

335 25

285

25

   0    2

DANGER High Voltage IN LINE POWER SUPPLY UNIT S ER .N o CODE.No HRC-A28/2 EQUIPMENTCLASS 'B' M AS S 1 0 Kg

C O MP AS S S AF E D IS TA NC ES GRADE I GRADE II DISSIPATION MANUFACTURED BY

KELVIN HUGHES LTD

HAINAULT ENGLAND

ASMITHS INDUSTRIESPLC COMPANY

MOD RECOR D

1

2

3

4

5

6

7

8

9

10

11

   0    0    3    7    5    5

TB3 3

TB 24V.

1

TB 0V.

12mm DIA TYPICAL

50

   1    3    1

UNIT SUPPLIED WITH FITTING KIT HRC-A494 CD-3834

Figure 2 - Line Amplifier/In Line PSU (HRC-A28-1): Installation Dimensions

Issue 3

Page A.5

KH1207 Annex A

              8              0    .             9             0    .             2             2

    M     R     A     R     O     T     I     N     O     M

       1

 .        S .         G 

    R B

     1      0     2         2    -     0      3      0      V      3     A      k     A      -     E      M      E      A      A      C      C    r     F     o     L     P

    O     E     D     I     V

    C     N     Y     S

  4 3

2 1

    X     A     O     C     E     T     I     H     W

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    R      C     R B      S

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7

    k    k    n     k     B     B    /     B     B     /     /    n     k     /     R    B    WB    R O R    B P V

    R     E     T     L     I     F

    R     C      S      R     C  S 

2

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    O      F     E     K     D     S      I     V

    I     O      H     L     N     N     A     A     C      C 

     R      C       S 

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1

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    Y     A     L     T     P    I     S     N     I    U     D     H     R     C     A    T     E    I     N     W     T    S     N     R     U     E     T     O     N     M     I    :     E    R     T    O     O     N

     )     J      (     X      S     A    E      O    L      C    B     A

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Figure 3 - Upmast Transceiver (CAE-A30-20, CAE-A30-21) with Long Cables using CAN Bus Interface: Typical Interconnections

Page A.6

Issue 3

KH1207 Annex A SETTING UP PROCEDURE FOR LINE AMPLIFIERS RAN-A26 AND RAN-A27-2

6

7

Issue 3

The setting up procedure requires the following: (1)

A square wave to be transmitted from RAN-A26.

(2)

The value of some of the components in Line Receiver RAN-A27 to be altered to restore the shape of the received waveform to a square wave.

Proceed as follows: (1)

Set Line Amp (RAN-A26) switches to ‘Test’ (SW1 set to Position 2, SW2 set to Position 1), to generate the square wave test signal. The video output will be a square wave signal of +1.5V peak to peak and approximately 40 s long into the display or a 75 ohm load. The sync output will be a square wave signal of +0.6V  peak to peak and approximately 40 s long into the display or a 75 ohm load.

(2)

Monitor the video output at the Line Receiver (RAN-A27). The pulse will have a slower rise time than the Head Amplifier due to cable losses.

(3)

Adjust potentiometer RV1 to give an output of 3V peak to peak on the flat part of  the pulse.

(4)

Check the video output pulse low level is between 0.6V and 1.0V above 0V.

(5)

To compensate cable high frequency loss: (a)

Fit resistor R16, 150R 2% Style FX (45-518-161-15).

(b)

Select a capacitor for C5 position to compensate for leading edge rise time. Use oscilloscope on 250 ns range.

(c)

If C5 is too large the pulse may have a ripple after the rising edge.

(d)

Further compensation can be carried out by fitting capacitors to C1, C2, C3, C4 and C8. See Figure 5 for guide to capacitor function.

(6)

Monitor the sync output at the Line Receiver (RAN-A27). The pulse will have a slower rise time than the Head Amplifier due to cable losses.

(7)

Adjust potentiometer RV2 to give an output of 2V peak to peak on the flat part of  the pulse.

(8)

Check that the sync output pulse low level is between 0.6V and 1.0V above 0V.

(9)

To compensate for cable high frequency loss: (a)

Fit resistor R32, 150R 2% Style FX (45-518-161-15).

(b)

Select a capacitor for C16 position to compensate for leading edge rise time. Use oscilloscope on 250 ns range.

(c)

If C16 is too large the pulse may have a ripple after the rising edge.

Page A.7

KH1207 Annex A (d)

8

Further compensation can be carried out by fitting capacitors C12, C13, C14, C15 and C119, See Figure 4 for guide to capacitor function.

(10)

Set Line Amp (RAN-A26) switches to ‘Normal’ (SW1 set to Position 1, SW2 set to Position 2). The normal video and sync signals will now be present.

(11)

The video amplitude will be approximately 5V peak to peak.

(12)

The sync amplitude will be approximately 6V peak to peak 

(13)

The dummy sync pulse (during sector mute) will be approximately 5V peak to  peak.

Figure 5 shows the effect of the compensation capacitors on the line receiver output waveform. Note that shorter cable lengths require le ss compensation than longer lengths.

C2 + C3 + C1 + C8 + C5 C3 + C1 + C8 + C5 C1 +C8 + C5 RV1 SET LEVEL

NO COMPENSATION C5 C8 +C5

CD-4193

Figure 4 - Effect of Compensation Capacitors on Output Waveforms

9

A guide to compensation components required. The cable type is coaxial cable 5344-719 (low loss)

Video R16 C5 C8 C1 C2 C3 C4

Page A.8

Sync R32 C16 C19 C12 C13 C14 C15

Cable length (metres) 170m 150R   220pF 220pF 68pF 68pF 30pF -

Issue 3

KH1207 Annex B

ANNEX B

SECTOR MUTING CONTENTS

Paragraph

 1 2 4 5 8 11 14

Page

INTRODUCTION INSTALLATION SETTING UP PROCEDURES 90 Pulses per revolution from Scanner (Normal Setting) Exam ple 1 180 Pulses per revolution from Scanner (Not Normal Setting) Exam ple 2

B.3 B.3 B.3 B.3 B.4 B.4 B.5

TABLES Table

1 2 3 4

Issue 3

Page

Example 1 - START of SECTOR 100 degrees Example 1 - END of SECTOR 260 degrees Example 2 - START of SECTOR 100 degrees Example 2 - END of SECTOR 260 degrees

B.4 B.4 B.5 B.5

Page B.1

KH1207 Annex B

THIS PAGE INTENTIONALLY BLANK 

Page B.2

Issue 3

KH1207 Annex B

ANNEX B

SECTOR MUTING INTRODUCTION

1

The Sector Mute Kit (CTX-A172) allows the selection of Sector Muting in 2 degree steps (180 pulses) or 4 degree steps (90 pulses).

INSTALLATION

2

The kit consists of the Sector Mute PCB (CTX-A162) and the threaded pillars to mount the PCB in the MkV Transceiver.

3

The Sector Mute PCB mounts onto the Antenna Terminals PCB using the pillars to space the boards apart. A connector is provided for Power Supplies and signals.

SETTING UP PROCEDURES

4

Paragraphs 5 to 9 provide setting up procedures for Sector Muting in 2 degree steps (180  pulses) and paragraphs 10 to 14 provide setting up procedures for Sector Muting in 4 degree steps (90 pulses). 90 Pulses per revolution from Scanner (Normal Setting)

5

The Mute sector may be set in 4 degree steps only, starting at 1 degree, i.e. 1, 5, 9, 13, 17, 21....... degrees.

 NOTE: S1 (poles 1-8) sets the start of the muted sector. S2 (poles 1-8) sets the end of the muted sector.  Pole 8 of each switch sets the smallest angle.

6

Switches SW1 and SW2 give the following angular increments when set to OFF: Pole

7

Issue 3

8 OFF sets to 1 degree 7 OFF sets to 5 degrees 6 OFF sets to 13 degrees 5 OFF sets to 29 degrees 4 OFF sets to 61 degrees 3 OFF sets to 125 degrees 2 OFF sets to 253 degrees 1 OFF sets to 509 degrees (WILL NOT START SECTOR AS ABOVE 360)

Example 1 shows how to set the required muted sector:

Page B.3

KH1207 Annex B Example 1

8

To mute a sector from 100 to 260 degrees (Bow docking), refer to Table 1 to start the sector and Table 2 to end the sector. Table 1 - Example 1 - START of SECTOR 100 degrees Set SW1 poles Pole OFF = (degrees) 96 = or 103 =

1 509

2 253

3 125

4 61

5 29

6 13

7 5

8 1

 ON

 ON

ON

OFF

 OFF

 ON

OFF

OFF

 ON

 ON

ON

OFF

 OFF

 OFF

 ON

 ON

Table 2 - Example 1 - END of SECTOR 260 degrees  Set SW2 poles Pole OFF = (degrees) 259 =  or 264 =

1 509

2 253

3 125

4 61

5 29

6 13

7 5

8 1

ON

OFF

ON

ON

ON

ON

OFF

OFF

ON

OFF

ON

ON

ON

OFF

ON

ON

9

In this example the required angle cannot be set exactly and the choice of the best compromise must be made.

10

If NO Sector Mute is required but the board is fitted, set SW1 to higher than 360 degrees, i.e. Pole 1 OFF. The Start sector does not trigger.

180 Pulses per revolution from Scanner (Not Normal Setting)

11

The Mute sector can be set in 2 degree steps only, starting at 1 degree. i.e. 1, 3, 5, 7, 9..... degrees.

 NOTE S1 (poles 1-8) sets the start of the muted sector. S2 (poles 1-8) sets the end of the muted sector.  Pole 8 of each switch sets the smallest angle. 12

Switches SW1 and SW2 give the following angular increments when set to OFF: Pole

Page B.4

8 OFF sets to 7 OFF sets to 6 OFF sets to 5 OFF sets to 4 OFF sets to 3 OFF sets to 2 OFF sets to 1 OFF sets to

1 degree 3 degrees 7 degrees 15 degrees 31 degrees 63 degrees 127 degrees 255 degrees Issue 3

KH1207 Annex B 13

Example 2 shows how to set the required muted sector:

Example 2

14

To mute a sector from 100 to 260 degrees, refer to Tables 3 and 4. Table 3 - Example 2 - START of SECTOR 100 degrees  Set SW1 poles 1

Pole OFF = (degrees) 98 = or 101 =

2

3

4

5

6

7

8

255

127

63

31

15

7

3

1

ON

ON

OFF

OFF

 ON

ON

 OFF

 OFF

ON

ON

OFF

OFF

ON

OFF

ON

ON

Table 4 - Example 2 - END of SECTOR 260 degrees  Set SW2 poles 1

2

3

4

5

6

7

8

Pole OFF = (degrees)

255

127

63

31

15

7

3

1

259 = or 262 =

OFF

ON

ON

ON

ON

ON

OFF

OFF

OFF

ON

ON

ON

ON

OFF

ON

ON

15

The compromise nearest setting to be used must be chosen.

16

If NO Sector Mute is required but the board is fitted, set SW1 to higher than 360 degrees, i.e. Poles 1 and 2 to OFF. The Start sector does not trigger.

Issue 3

Page B.5

KH1207 Annex B

INTENTIONALLY BLANK 

Page B.6

Issue 3

KH1207 Reports

INSTALLATION AND SERVICE REPORTS This section is reserved for customer use and the following information should be inserted into the manual: 1

Installation Reports and Records

2

Service Reports and Records

3

Copy of Warranty Card

4

Other relevant documentation

Issue 3

Page 1