SHIP'S TECHNICAL MANUAL INSTALLATION, COMMISSIONING and MAINTENANCE INFORMATION for TM SharpEye X-BAND UPMAST TRANSCEIVER fitted with ANTENNA LPA-A25 PUBLICATION KH1264 Issue 2 July 2009 Kelvin Hughes Limited New North Road, Hainault, Ilford, Essex IG6 2UR, UK Telephone: +44 20 8502 6887 Facsimile: +44 20 8559 8526 Telex: 896401 www.kelvinhughes.com Registered Office: New North Road, Hainault, Ilford, Essex IG6 2UR Incorporated in England No.
COPYRIGHT ã 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.
AMENDMENT RECORD When an amendment is incorporated into this publication, the details should be recorded below. Where the equipment has been modified, the modification number shown on the Amendment Instruction Sheet is also to be recorded. Amdt. No. Issue 2 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 Certificate 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 Installation and Service Reports Issue 2 Page v
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FOREWORD This Ship's Manual provides installation, commissioning and maintenance information for the SharpEyeTM X-band Transceiver and Antenna. 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 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.
IMPORTANT NOTICES HEALTH AND SAFETY 1 All personnel are required to study these notices and familiarise themselves with all applicable 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 second can kill. This can occur at voltages as low as 35 V AC or 50 V DC. Some equipment in the system uses electrical power that can be lethal.
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 2 m 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.
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).
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.
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.
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’.
KH1264 Chapter 1 CHAPTER 1 GENERAL DESCRIPTION CONTENTS Paragraph 1 9 9 19 Page INTRODUCTION SYSTEM DESCRIPTION Transceiver Drive Control Unit 1.3 1.4 1.4 1.5 ILLUSTRATIONS Figure 1 2 Issue 2 Page SharpEyeTM Transceiver: Block Diagram SharpEyeTM Transceiver: Typical Configuration 1.6 1.7 Page 1.
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KH1264 Chapter 1 CHAPTER 1 GENERAL DESCRIPTION INTRODUCTION The SharpEyeTM Radar combines the latest concepts, technologies and state of the art performance in surface search capability into a high reliability product for the maritime industry.
KH1264 Chapter 1 SYSTEM DESCRIPTION Transceiver 9 The transceiver electronics and the transceiver power supply are mounted in a cast enclosure with one removable side cover, secured by seven captive bolts. The transceiver electronics are contained in a unit mounted on the side of the enclosure and the power supply is mounted on the base of the enclosure. The gearbox and motor are mounted on top of the enclosure with the antenna secured to the top of the gearbox on a swing casting.
KH1264 Chapter 1 14 The transceiver electronics comprise radar control and timing, waveform generator, solid state transmitter, duplexer, low noise RF receiver, digital receiver, signal processor and communications interface. 15 The waveform generator provides frequency modulated pulses at an intermediate frequency (IF), whose characteristics are determined by the range modes.
KH1264 Chapter 1 WARNING ALWAYS SET THE KEYSWITCH TO OFF AND REMOVE THE KEY WHEN WORKING ON THE UPMAST TRANSCEIVER. THIS PREVENTS THE ANTENNA FROM ROTATING. THE INVERTER MUST BE SET TO REMOTE OPERATION DURING COMMISSIONING, OTHERWISE THE KEYSWITCH FUNCTION WILL BE OVERRIDDEN.
KH1264 Chapter 1 Figure 2 - SharpEyeTM Transceiver: Typical Configuration Issue 2 Page 1.
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KH1264 Chapter 2 CHAPTER 2 SPECIFICATION CONTENTS Paragraph 1 Issue 2 Page TECHNICAL SPECIFICATIONS Features Transmitter Receiver Signal Processor Antenna Turning Mechanism Operating Temperature Ranges Input Power 2.3 2.3 2.3 2.3 2.4 2.4 2.4 2.4 2.4 Page 2.
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KH1264 Chapter 2 CHAPTER 2 SPECIFICATION TECHNICAL SPECIFICATIONS 1 The technical specifications for the SharpEyeTM X-band Upmast Transceiver is as follows: Features Range resolution: 40 m Dynamic range: ³ 100 dB (including Sensitivity Time Constant (STC)) ensures simultaneous detection of large and small targets Radar control: CANbus System Type: Fully coherent Transmitter Frequency: 1 of 14 frequencies, each 20 MHz wide, selectable in the band 9.22 GHz to 9.
KH1262 Chapter 2 Signal Processor Digital Phase Sensitive Detector Digital Pulse Compression Maximum instrumented range: 48 nm Compressed pulse lengths: 0.1 ms or 0.2 ms Antenna Antenna Type: Polarisation: Turning Circle: Horizontal beamwidth: Vertical beamwidth: Sidelobes: Antenna gain: Frequency range: End fed slotted array Horizontal 2.6 m 0.95° 26° £ -30 dB, 1st sidelobe £ -26 dB typical >10° sidelobes £ -33 dB typical 30 dB 9.22 GHz to 9.
KH1264 Chapter 3 CHAPTER 3 TECHNICAL DESCRIPTION CONTENTS Paragraph 1 1 5 6 7 7 11 13 15 18 28 29 30 31 37 38 39 40 Page PHYSICAL DESCRIPTION TRANSCEIVER DRIVE CONTROL UNIT FUNCTIONAL DESCRIPTION TRANSCEIVER Motor and Gearbox Transceiver (DTX-A115) Timing Circuits and Azimuth Data Processing Transmitter Circuits Receiver Circuits Operating States Operating Range Installation and Setting to Work Parameters Monitoring CAN Bus Interface +15 V Supplies Power Supply (45-690-0062-002) DRIVE CONTROL UNIT (GTX-A
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KH1264 Chapter 3 CHAPTER 3 TECHNICAL DESCRIPTION PHYSICAL DESCRIPTION TRANSCEIVER 1 The transceiver is mounted in a cast enclosure with one removable side cover that allows access to the transceiver electronics (refer to Figure 1). The cover is fitted with a seal to prevent the ingress of moisture, and is secured to the cast enclosure by seven bolts. A strap attached to the cover and enclosure prevents the cover from being dropped when removed from the enclosure.
KH1264 Chapter 3 ROTATING JOINT MOTOR & GEARBOX 3 PHASE 55-100-0273-001 B ENCODER AZ/HL GTX-A188 INTERNAL WAVEGUIDE ASSEMBLY DTX-A170 X-BAND Tx ASSEMBLY DTX-A115 DTX-A115 KELVIN HUGHES RADAR TRANSCEIVER AZIMUTH INTERFACE PCB DTX-A151 CAN ADAPTOR PCB NNR-A981 A A FMS090-5600 SERIAL No. MOD:- B SECTION ON B-B DOOR REMOVED FOR CLARITY POWER SUPPLY TYPE XLC 503-POS A 45-690-0062-002 CD-7617 ISSUE 1 SECTION ON A-A Figure 1 - Transceiver (DTX-A3): Module Locations Page 3.
KH1264 Chapter 3 NEON INDICATOR GREEN 45-6000-0076-001 KEYSWITCH 45-613-4205 LED INDICATOR GREEN 45-6000-0049-001 INVERTER 45-690-0033-001 E R/L1 S/L2 TOSHIBA POWER INPUT CABLEFORM GTX-A217 PRG MON P POWER OUTPUT CABLEFORM GTX-A196 RUN STOP VT/2 W/T N E SCHAFFNER FN2070M-12-06 UT/1 P RUN N ENT U V W OUTPUT TB2 1 PLA MAINS FILTER 45-680-0028-001 6 CONTROL CABLEFORM GTX-A197 DRIVE INTERFACE PCB GTX-A104 L N E E MAINS INPUT TB1 1TB4 12 WAY TAGBLOCK VIDEO AND SYNC COAXIAL
KH1264 Chapter 3 FUNCTIONAL DESCRIPTION 6 Functional diagrams of the transceiver and antenna are shown in Figure 3 and the interconnections in Figure 4. TRANSCEIVER Motor and Gearbox 7 The antenna motor is driven by a 3 phase supply from the inverter in the Drive Control Unit. The Drive Control Unit is configured to provide a soft start and a soft stop for the motor, so that the motor takes a few seconds to reach normal antenna rotation speed and a few seconds to slow down when stopped.
KH1264 Chapter 3 Transceiver (DTX-A115) 11 The transceiver uses solid state components and provides a signal generator and frequency synthesiser, up-converter, solid state RF power amplifier, duplexer, low noise RF receiver, down-converter, digital receiver, digital signal processor and a LAN interface. The transceiver produces a peak power output of ³170 W. The solid state design provides excellent reliability and has no lifed items.
KH1264 Chapter 3 Receiver Circuits 18 Return signals from the antenna are fed through the rotating joint to the transceiver, which routes the received signal via the duplexer to an internal low noise RF receiver, digital receiver and signal processor. 19 Sensitivity Time Control (STC) is applied to the low noise RF receiver to increase the dynamic range of the receiver. The noise figure of the receiver is £4 dB, measured at the output of the analogue to digital converter.
KH1264 Chapter 3 Operating States 28 The transceiver has the following six operating states: (1) Off. In this state power is not applied to the transceiver and it is switched off. (2) Initialise. When power is applied to the transceiver it enters initialise state. The transceiver automatically loads any software or configuration files and supplies DC power to the azimuth encoder. On completion of initialisation the transceiver switches to Standby state. (3) Standby.
KH1264 Chapter 3 Installation and Setting to Work Parameters 30 The SharpEyeTM Transceiver contains a number of operational settings that are set up during system installation and setting to work. These operational settings are: (1) Rotation Rate. The transceiver supports 2 nominal antenna rotation rates, 22 rpm and 44 rpm. System behaviour and performance varies depending upon which rotation rate is selected as the system parameters are adjusted for the different rotation rates.
KH1264 Chapter 3 Monitoring 31 If the RF output power falls below 100 W the transceiver sends an RF Power warning message to the display system and switches to the Degraded state of operation. 32 If the VSWR on the RF output is above 2.0:1 the transceiver sends an Antenna VSWR warning message to the display system and switches to the Degraded state of operation.
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KH1264 Chapter 3 X-BAND ANTENNA ENCODER AZ/HL GTX-A188 1 PHASE MAINS SUPPLY MOTOR ON/OFF DRIVE CONTROL UNIT GTX-A24 3 PHASE TO MOTOR AERIAL TURNING MOTOR 55-100-0273-001 AZIMUTH/ HEADING LINE GENERATION PHASE & QUADRATURE AZ BALANCED HL +15V X-BAND UPMAST TRANSMITTER/RECEIVER DTX-A3 +3.
KH1264 Chapter 3 AERIAL MOTOR 3-PHASE 55-100-0273-001 3-PHASE FROM DRIVE CONTROL UNIT R Y B U V W SCREEN E POWER SUPPLY 45-690-0062-002 TB5 110V/220V MAINS INPUT LIVE NEUTRAL EARTH SHARPEYE X-BAND Tx ASSEMBLY DTX-A115 J1 SW1 1 2 3 LIVE NEUTRAL EARTH L N E MODULE A AJ4 PL2 1 2 A1 A2 A4 A3 0V (3.3V) 3.
KH1264 Chapter 3 DRIVE CONTROL UNIT (GTX-A24) 40 The drive control unit provides 3 phase supplies for the antenna turning motor in the SharpEyeTM Upmast Transceiver. It accepts a 220 V single phase mains supply and generates a 3 phase supply at either 25 Hz or 50 Hz with the frequency set internally, either of which may be selected from the display, or by physical wire links on the Drive Control Unit.
KH1264 Chapter 3 47 The inverter is switched on by applying +12 V to +28 V across PLA pins 1 and 2 on the Drive Control PCB. The positive voltage is routed via PLC pin 5 to the Man Aloft Keyswitch (SW1), which is located on the top of the unit. This switch disables the +12 V to +28 V to the inverter when set to the OFF position, thus switching the inverter off, regardless of the input condition, provided the inverter has been set for remote operation.
KH1264 Chapter 3 TB3 1 MAINS ON LP1 2 220V MAINS INPUT TB1 1 2 3 LIVE NEUTRAL EARTH INVERTER 45-690-0033-001 L1 T1 L MAINS FILTER L N 45-680-0028-001 N E L1 L1 L2 L3(N) NOT USED PE COMMON FORWARD SPEED 1 SPEED 2 P15 F S1 S2 +15V O/P FORWARD SPEED 1 SPEED 2 T2 T3 L2 TB2 1 L3 2 L4 3 220V 3 PHASE OUTPUT TO MOTOR FERRITE CORES (2 TURNS THROUGH EACH RING) START (27V) START (RTN) SPEED 1 PLA 1 3 1 PLB PLC 6 5 1 2 3 4 6 7 8 KEYSWITCH SW1 PLD NOT USED LED DRIVER 2 OPTOISOLATOR 3
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KH1264 Chapter 4 CHAPTER 4 INSTALLATION CONTENTS Paragraph 1 4 5 7 13 13 18 20 21 21 27 28 30 31 32 32 34 35 37 38 44 45 46 47 48 50 Page GENERAL COMPASS SAFE DISTANCES TRANSCEIVER SAFETY NOTES EQUIPMENT LOCATION UPMAST TRANSCEIVER (DTX-A3) DRIVE CONTROL UNIT (GTX-A24) OPTIONAL MAINS ISOLATOR (80-261-600) INSTALLATION UPMAST TRANSCEIVER (DTX-A3) Fitting the Upmast Transceiver to the Ship Fitting the Low Profile Antenna DRIVE CONTROL UNIT (GTX-A24) OPTIONAL MAINS ISOLATOR (80-261-600) ELECTRICAL CONNECTI
KH1264 Chapter 4 CONTENTS (continued) LIST OF ILLUSTRATIONS Figure 1 2 3 4 5 6 7 8 9 10 Page Transceiver (DTX-A3): Installation Dimensions Transceiver (DTX-A3): Mast Mounting Transceiver (DTX-A3): Fitting Kit Suggested Antenna Lifting Arrangement Drive Control Unit (GTX-A24): Installation Dimensions Mains Isolator: Installation Dimensions Transceiver (DTX-A3): Cableform Routing Drive Control Unit (GTX-A24): Cableform Routing Cable Gland: Assembly Transceiver (DTX-A3): External Connections Page 4.2 4.9 4.
KH1264 Chapter 4 CHAPTER 4 INSTALLATION GENERAL 1 This section provides installation information for SharpEyeTM X-band Upmast Transceiver. 2 Kelvin Hughes, or appointed agents, contracts only to supply the equipment, supervise the installation and final connection of the equipment. The installation must be 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.
KH1264 Chapter 4 SAFETY NOTES Observe the Health and Safety Notices at the front of this manual. In particular, the procedures given in the Code of Safe Working Practices CP225 MUST be followed. Failure to follow these procedures and to complete and return the Warranty card will invalidate the warranty on the equipment. 7 Safety personnel must ensure that persons do not encroach on the area of work.
KH1264 Chapter 4 EQUIPMENT LOCATION UPMAST TRANSCEIVER (DTX-A3) 13 The Upmast Transceiver should be installed in such a position where Blind Arcs, caused by obstructions, i.e. masts, funnels etc, are eliminated or minimised. Funnels, crosstrees and other large obstructions can also reflect energy and give rise to spurious echo returns especially in close proximity to land. Positioning the antenna close to funnels and exhaust gases can adversely affect antenna performance.
KH1264 Chapter 4 INSTALLATION UPMAST TRANSCEIVER (DTX-A3) WARNING ENSURE THAT ALL POWER SUPPLIES IN THE VICINITY OF THE TRANSCEIVER ARE ISOLATED BEFORE ANY INSTALLATION TAKES PLACE. 21 The SharpEyeTM Upmast Transceiver is supplied in two parts: (1) Transceiver with Gearbox. (2) Antenna. 22 The SharpEyeTM Upmast Transceiver is fitted with a Low Profile Antenna (LPA-A25).
KH1262 Chapter 4 Fitting the Upmast Transceiver to the Ship 27 To install the upmast transceiver, proceed as follows: (1) Mark out and drill four 17 mm gearbox mounting holes at the mounting position. 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 TURNING MECHANISM, THE TURNING MECHANISM MUST NOT BE LIFTED BY THE ANTENNA.
KH1262 Chapter 4 (1) Fit the antenna mounting bracket on top of the swing casting by inserting the 8 supplied M10 x 40 mm button head allen key screws through the aligning holes, and tightening the 8 supplied M10 barb nuts on the underside of the swing casting. Apply Loctite to all screws. (2) Remove the protective caps, tapes, etc. from the antenna and waveguide. Ensure the waveguide faces are clean and free from grease.
Issue 2 FWD CD-7629 ISSUE 1 CENTRE OF GRAVITY DIMENSIONS ARE ESTIMATED ALL DIMENSIONS IN MILLIMETRES UNLESS OTHERWISE STATED ALL DIMENSIONS NOMINAL NOTE: REFER TO FIGURE 4 FOR MOUNTING DETAILS C of G 192 85 -kg -kg STANDARD COMPASS GRADE I STEERING COMPASS GRADE II & III GRADE IV COMPASS SAFE DISTANCES: CABLES FED THROUGH NOTCH IN MOUNTING PLATE 14-CORE & 2-CORE CABLES FED THROUGH CABLE GLANDS AT REAR OF CASE 3-CORE MOTOR POWER CABLE FED THROUGH CABLE GLAND ON MOTOR TERMINAL BLOCK OPERATING TE
KH1264 Chapter 4 DO NOT LIFT HERE FWD 3-CORE MOTOR POWER CABLE TO MOTOR 14-CORE & 2-CORE CABLES FED THROUGH CABLE GLANDS AT REAR OF CASE CABLES FED THROUGH NOTCH IN MOUNTING PLATE 450 830 540 460 4 x FIXING HOLES Ø17 MAX 2m 460 474 674 30 200 50 TUBE DIAMETER 200mm MINIMUM 490 750 TUBE THICKNESS 12mm MINIMUM 500 MOUNTING PLATE & STIFFENING PIECES 15mm STEEL ALL DIMENSIONS IN MILLIMETRES UNLESS OTHERWISE STATED CD-7032 ISSUE 1 Figure 2 - Transceiver (DTX-A3): Mast Mounting Page 4.
Issue 2 GTX-1203 PP-6013 ZV-9758 1 4 4 3 4 8 1 1 5 6 7 8 9 10 11 USED ON 12 CAE-1189 1 4 DRAWN BY 6 T.
KH1264 Chapter 4 CODE No DRAWING PRACTICE TO BS 308 DO NOT SCALE LPA-1097 THIRD ANGLE PROJECTION USED ON THIS DOCUMENT IS THE PROPERTY OF KELVIN HUGHES LTD. A SUBSIDIARY OF SMITHS INDUSTRIES PUBLIC LIMITED COMPANY. IT IS TO BE TREATED AS CONFIDENTIAL AND MAY NOT BE REPRODUCED OR USED OR DISCLOSED TO THIRD PARTIES WITHOUT THE PREVIOUS CONSENT OF KELVIN HUGHES LTD.TO WHOM IT MUST BE RETURNED C KELVIN HUGHES LIMITED 2004 SEE NOTE 2 LPA-1052 SEE NOTE 3 IN 2 POS'NS NOTES 1.ANTENNA WEIGHT = 70 Kg 2.
KH1264 Chapter 4 DRIVE CONTROL UNIT (GTX-A24) WARNING ENSURE THAT ALL POWER SUPPLIES IN THE VICINITY OF THE DRIVE CONTROL UNIT ARE ISOLATED BEFORE ANY INSTALLATION TAKES PLACE. 30 Fit the drive control unit to the securing bulkhead using the installation bolts supplied with the fitting kit. Refer to Figure 5 for dimensions. Allow sufficient space at the base of the unit to allow the cables to be inserted through the cable glands and at the top of the unit for withdrawal of the key from the keyswitch.
KH1264 Chapter 4 OPTIONAL MAINS ISOLATOR (80-261-600) With reference to Figure 6, secure the Mains Isolator in the required position (no fittings are supplied). 30 160 205 31 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.
KH1264 Chapter 4 ELECTRICAL CONNECTION CABLE SPECIFICATIONS 32 Each cable is identified by a letter code which defines the type of cable required, e.g. Cable code H is a 14-core cable. Table 1 provides specifications for each cable type. Table 2 provides 14-core cable, colour code abbreviations. 33 The cables used to connect Kelvin Hughes equipment are to be to the following specification. Failure to use the correct specification cables may result in impaired equipment performance.
KH1264 Chapter 4 14 Core Composite Cable 34 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: 4 cores of 32/0.2 mm (1.0 mm2) copper wire. 1 screened twisted pair 16/0.2 mm (0.5 mm2) copper wire for serial data links. 3 twisted pairs in 1 screen 16/0.2 mm (0.5 mm2) copper wire for serial data links. 2 cores of co-axial cable 7/0.25 mm (0.35 mm2).
KH1264 Chapter 4 Small Multi-Core Cables 35 These cables conform to DEF STAN 61-12 (part 5). Each cable consists of a number of insulated cores, collectively screened and clad in a PVC outer sheath. 36 Core Details (1) The core details are as follows: Conductors consist of 16 strands of 0.2 mm diameter tinned copper wire. Nominal cross-section area of conductor = 0.5 mm2. Nominal diameter of conductor = 0.93 mm Nominal thickness of insulation = 0.45 mm Minimum thickness of insulation = 0.
KH1264 Chapter 4 GENERAL 38 Before starting electrical connection observe the following: WARNING ENSURE THAT ALL POWER SUPPLIES ARE ISOLATED BEFORE ANY ELECTRICAL CONNECTION TAKES PLACE. 39 40 Isolate power supplies as follows: (1) Ensure that the associated display is turned off. (2) Remove fuses from mains isolators. The casing of the upmast transceiver must be securely earthed to the platform with braided copper wire.
KH1264 Chapter 4 3-CORE POWER CABLE CODE L (CONNECTIONS BEHIND COVER) 2-CORE POWER CABLE CODE K 14-CORE COMPOSITE CABLE CODE H TB5 TB3 TB2 TB1 CD-7030 ISSUE 3 Figure 7 - Transceiver (DTX-A3): Cableform Routing Issue 2 Page 4.
KH1264 Chapter 4 INVERTER E R/L1 S/L2 TOSHIBA PRG MON P RUN STOP VT/2 W/T N E SCHAFFNER FN2070M-12-06 UT/1 P RUN N ENT 1 DRIVE INTERFACE PCB PLA 6 1TB4 12 WAY TAGBLOCK L E TB1 COAXES 1-PHASE MAINS IN 2 CORE CABLE TYPE K 14 CORE CABLE TYPE H 14 CORE CABLE TYPE H 3-PHASE OUT 3 CORE CABLE TYPE L CD-7024 ISSUE 4 Figure 8 - Drive Control Unit (GTX-A24): Cableform Routing Page 4.
KH1264 Chapter 4 PREPARE CABLE (LENGTHS OF CORES AND SCREEN TO BE CUT TO SUIT APPLICATION) BRAIDED SCREEN CABLE CORES ASSEMBLE GLAND AS SHOWN FLAT SIDE PRESSURE SCREW SEALING INSERT RECESSED SIDE (TO ALLOW FOR SPRING) RECESSED WASHER UNIT CASING FLAT SIDE CIRCULAR SPRING RECESSED WASHER GLAND BODY NOTE: THE BRAIDED SCREEN IS BONDED BY A CIRCULAR SPRING BETWEEN THE TWO RECESSED WASHERS. THE CABLE GLAND’S SEALING INSERT PRESSES ON THE WASHERS.
KH1264 Chapter 4 WIRING DIAGRAMS 48 Electrical connections for upmast and downmast transceiver systems are detailed on the wiring diagram (Figure 10). For full details of connections to the display system refer to your system manual (KH2020, KH2026 and KH2061), as appropriate. 49 The inverter in the Drive Control Unit must be set to produce either low speed or high speed antenna rotation to meet the operational requirements of the system.
Issue 2 220V 15A 50/60Hz 1 PHASE (100mA EARTH LEAKAGE) CUSTOM CABLE H 14-CORE CABLE K 2-CORE POWER TO PROCESSOR or INTERSWITCH SCR R B Y G Bn Bn/W V V/W O B/O W S S W COAXES COAX COAX SCR SCR U V W TB2 1 2 3 NOTE: ON DRIVE CONTROL UNIT, MAKE LINKS ON PLA OF GTX-A104 AS FOLLOWS: LOW SPEED: PLA-2 to PLA-4 HIGH SPEED: PLA-2 to PLA-4 & PLA-3 to PLA-4 1 L 2 N TB1 PART OF PLA 1 MOTOR START +27V 2 MOTOR START RTN GTX-A104 CAN HI CAN LO 1TB4 3 2 1 AZ1 SCR 4 nAZ1 5 HL AZ2 6 nAZ2 7 8 nHL 9 1
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KH1264 Chapter 5 CHAPTER 5 COMMISSIONING CONTENTS Paragraph 1 2 3 5 9 Page INTRODUCTION POWER SUPPLIES SETTING TO WORK Drive Control Unit Transceiver Checks 5.3 5.3 5.3 5.4 5.6 ILLUSTRATIONS Figure 1 Issue 2 Page Drive Control Unit: Inverter Location 5.7 Page 5.
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KH1264 Chapter 5 CHAPTER 5 COMMISSIONING INTRODUCTION 1 Interswitched equipments, or equipments interfaced with other radar equipments, are described in their respective Handbooks. POWER SUPPLIES 2 Check that all cables have been installed and connected. SETTING TO WORK WARNING WHEN WORKING ON THE UPMAST TRANSCEIVER ALWAYS ENSURE THE ON/OFF SWITCH ON THE DRIVE CONTROL UNIT IS SET TO OFF AND THE KEY IS WITHDRAWN. THE KEY SHOULD BE RETAINED BY THE INSTALLER WHEN WORKING ALOFT.
KH1264 Chapter 5 Drive Control Unit NOTE: The inverter is set up in the factory for operation with an input frequency of 50 Hz. WARNING THE INVERTER MUST BE SET TO REMOTE OPERATION. IF THE INVERTER IS SET TO LOCAL OPERATION IT WILL BE SWITCHED ON REGARDLESS OF THE POSITION OF THE ON/OFF KEYSWITCH, THUS OVERRIDING THE MAN ALOFT INTERLOCK FUNCTION. 5 The Drive Control Unit contains an inverter that must be programmed to provide the correct frequency of rotation for the antenna.
KH1264 Chapter 5 WARNING IF OPERATION FROM THE INVERTER FRONT PANEL IS SELECTED, THE MAN ALOFT SAFETY KEYSWITCH IS OVERRIDDEN. NEVER SELECT OPERATION FROM THE INVERTER FRONT PANEL FOR NORMAL OPERATIONAL USE. (11) 8 To select operation from the inverter front panel set function CN0d to 1 (Start/Stop local control) and FN0d to 1 (Frequency set by Ý ß). Set both functions to 0 to return to remote control (normal operation).
KH1262 Chapter 5 Transceiver Checks NOTE: The following checks require the display to be configured for the transceiver/antenna combination. 9 Set any Mains Isolators to ON. 10 At the Drive Control Unit, insert the key into the ON/OFF keyswitch and set the switch to ON. 11 Configure the display for the transceiver/antenna combination installed. 12 Verify that the display indicates TX READY after the warm up period of approximately 30 seconds. Check that no fault indications are displayed.
KH1264 Chapter 5 INVERTER E R/L1 S/L2 TOSHIBA PRG MON P UT/1 P RUN STOP VT/2 W/T N E SCHAFFNER FN2070M-12-06 RUN N ENT U V W OUTPUT TB2 PLA L N E MAINS INPUT TB1 CD-7023 ISSUE 3 Figure 1 - Drive Control Unit: Inverter Location Issue 2 Page 5.
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KH1264 Chapter 6 CHAPTER 6 MAINTENANCE CONTENTS Paragraph 1 2 2 2 3 4 5 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 Issue 2 Page INTRODUCTION PLANNED MAINTENANCE SIX MONTHLY CHECKS Antenna Transceiver Casing Inspection DIAGNOSTIC MAINTENANCE PRE-REQUISITES FAILURE MESSAGES TEST EQUIPMENT PREPARATION FOR FAULT DIAGNOSIS INDICATORS CORRECTIVE MAINTENANCE TRANSCEIVER (DTX-A3) Access Removal of Rotating Joint (45-750-0034-001) Replacement of Rotating Joint (
KH1264 Chapter 6 CONTENTS (CONT.) ILLUSTRATIONS Figure 1 2 3 4 Page CAN Adapter PCB (NNR-A981): LED Location Transceiver: Fault Diagnosis Transceiver (DTX-A3): Module Locations Drive Control Unit (GTX-A24): Module Locations Page 6.2 6.7 6.9/10 6.17 6.
KH1264 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 NOTE: The transceiver runs continuously runs performance checks in the background, and any degradation in performance is reported as a warning message. There are no routine operator or maintainer performance checks required on the transceiver.
KH1264 Chapter 6 DIAGNOSTIC MAINTENANCE WARNING THIS EQUIPMENT IS NOT FITTED WITH SAFETY INTERLOCKS AND LETHAL VOLTAGES ARE PRESENT WITHIN THE UNIT. ACCESS TO THE INTERIOR OF THE UNIT IS ONLY TO BE CARRIED OUT BY A QUALIFIED TECHNICIAN. 4 The flowcharts in this chapter provide an aid to fault diagnosis in the transceiver. The algorithms enable fault diagnosis down to module level and also identify wiring faults. Entry to the algorithms is via Failure Messages generated by the display.
KH1264 Chapter 6 8 (4) PLO Lock. Indicates that the phase locked oscillator has developed a hardware fault. (5) Synth Lock. Indicates that the frequency synthesiser has developed a hardware fault. (6) Transmitter Over-temperature. This indicates that the temperature of the RF power transistors is high, indicating a fault in the transceiver. Fault diagnosis algorithms covering these failures is provided in Figure 3. TEST EQUIPMENT 9 Fault location is to module replacement level only.
KH1264 Chapter 6 10 To access the units inside the upmast transceiver, remove the side cover of the transceiver. This allows access to the transceiver and the power supply and allows the LEDs on the PSU Sense PCB and CAN Adapter PCB to be seen. WARNING IT IS DANGEROUS TO RUN THE TRANSCEIVER WHEN UPMAST AS THE ANTENNA IS ROTATING AND RF IS RADIATED. UNDER NO CIRCUMSTANCES SHOULD THE MAINTAINER BE UPMAST WHEN RF IS RADIATED AND/OR THE ANTENNA IS ROTATING.
D11 D16 D38 PLA 1 D12 KH1264 Chapter 6 1 PLC LK1 SKE SKF SKG SKH D15 D14 D13 1 PLJ LK2 IC1 SW1 SKD D5 D4 PLB 1 VIEW ON COMPONENT SIDE CD-7423 ISSUE 1 Figure 1 - CAN Adapter PCB (NNR-A981): LED Location Issue 2 Page 6.
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KH1264 Chapter 6 RADAR FAULT DETECTED AT DISPLAY (AT STANDBY) NO IS Tx READY IND PRESENT? ON PSU SENSE PCB ARE D2, D3 & D4 LIT? YES NO CHECK CONNECTIONS, MAINS INPUT & POWER SUPPLY REPAIR CONNECTIONS IF NECESSARY.
KH1264 Chapter 6 CORRECTIVE 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. CAUTIONS (1) Handling Of Electrostatic Sensitive Semiconductor Devices. Semiconductor devices used in the equipment are liable to damage due to static voltage.
KH1264 Chapter 6 TRANSCEIVER (DTX-A3) 13 The locations of the modules and assemblies in the upmast transceiver and turning mechanism are shown in Figure 3. Access 14 Access to the modules and assemblies in the Upmast Transceiver, except the motor and gearbox, is attained by releasing the seven bolts securing the side cover in position and then removing the cover.
KH1262 Chapter 6 Replacement of Rotating Joint (45-750-0034-001) 16 To replace the rotating joint, reverse the above procedure. Tighten and torque load the 12 antenna retaining bolts to 56 Nm and apply Loctite 222 on their threads during assembly. Waterproof the coaxial joint to the antenna by sealing with a layer of greased plastic compound such as Henleys compound or Denso-Tape.
KH1264 Chapter 6 Transceiver (DTX-A115) - Removal 21 To remove the Transceiver, proceed as follows: (1) Remove all power supplies to the transceiver. NOTE: The D -type connectors have a sliding metal retainer which must be moved fully one way before the connector can be removed. Note that the transceiver is removed in two sections. (2) Disconnect the internal waveguide from the transceiver by removing the four sets of bolts and nuts.
KH1264 Chapter 6 Power Supply (45-690-0062-002) and PSU Sense PCB (DTX-A121) - Removal 23 To remove the Power Supply, proceed as follows: (1) Remove the connectors from the Power Supply. (2) Release the two captive screws securing the Power Supply to the base of the case. (3) Pull the unit out, releasing the two securing flanges securing the power supply to the baseplate, and remove the power supply.
KH1264 Chapter 6 SharpEye Azimuth Interface PCB (DTX-A151) - Removal 28 To remove the SharpEyeTM Azimuth Interface PCB, proceed as follows: (1) Remove the connectors from the SharpEyeTM Azimuth Interface PCB. (2) Remove and retain the two screws securing the SharpEyeTM Azimuth Interface PCB and remove the PCB. SharpEye Azimuth Interface PCB (DTX-A151) - Replacement 29 To replace the SharpEyeTM Azimuth Interface PCB reverse the above procedure. Page 6.
KH1264 Chapter 6 ROTATING JOINT MOTOR & GEARBOX 3 PHASE 55-100-0273-001 B ENCODER AZ/HL GTX-A188 INTERNAL WAVEGUIDE ASSEMBLY DTX-A170 X-BAND Tx ASSEMBLY DTX-A115 DTX-A115 KELVIN HUGHES RADAR TRANSCEIVER AZIMUTH INTERFACE PCB DTX-A151 CAN ADAPTOR PCB NNR-A981 A A FMS090-5600 SERIAL No.
KH1264 Chapter 6 DRIVE CONTROL UNIT (GTX-A24) 30 The locations of the modules and assemblies in the Drive Control Unit are shown in Figure 4. Access 31 Access to the modules and assemblies is attained by releasing the four screws securing the cover in position and then removing the cover. Inverter Assembly - Removal 32 To remove the Inverter Assembly, proceed as follows: (1) Remove power from the Drive Control Unit.
KH1264 Chapter 6 Mains Filter (45-680-0028-01) - Replacement 37 To replace the Mains Filter reverse the above procedure, ensuring the earth tag is refitted and secured.
KH1264 Chapter 6 CHECKS AFTER UNIT REPLACEMENT 38 Any maintenance, or rectification, involving the replacement of PCBs or Modules within the Transceiver involves certain procedures to bring the Transceiver up to full working order. The PCBs and Modules have been factory tested, and preset, and do not require any adjustment. Therefore, no setting up procedures are required for the transceiver.
KH1264 Chapter 7 CHAPTER 7 PARTS LIST CONTENTS Paragraph 1 Page INTRODUCTION 7.3 PARTS LISTS Page Parts List PL1 PL2 X-band Upmast Transceiver (DTX-A3): Parts List Drive Control Unit (GTX-A24): Parts List 7.5 7.7 ILLUSTRATIONS Figure 1 2 Issue 2 Page X-band Upmast Transceiver (DTX-A3): Main Assemblies Drive Control Unit (GTX-A24): Main Assemblies 7.4 7.6 Page 7.
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KH1264 Chapter 7 CHAPTER 7 PARTS LIST INTRODUCTION 1 This Chapter provides a Parts Lists and drawing, showing layout and location information, to support the SharpEyeTM X-band Transceiver. 2 The Parts List is presented in tabular form and provides 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 2 Page 7.
KH1264 Chapter 7 4 3 2 B 1 8 5 DTX-A115 6A 6 6B 9,12 KELVIN HUGHES RADAR TRANSCEIVER A A ACH FMS090-5600 SERIAL No. MOD:- ISOLATE MAINS BEFORE SERVICING 10,14 9,13 7 B DOOR REMOVED FOR CLARITY 5 7 SECTION ON A-A CD-7427 ISSUE 1 Figure 1 - X-band Upmast Transceiver (DTX-A3): Main Assemblies Page 7.
KH1264 Chapter 7 PL1 - X-band Upmast Transceiver (DTX-A3): Parts List ITEM NUMBER DESCRIPTION KELVIN HUGHES Part No.
KH1264 Chapter 7 3 5 4 1 E R/L1 S/L2 TOSHIBA PRG MON P UT/1 P STOP VT/2 W/T N E SCHAFFNER FN2070M-12-06 7 RUN N ENT RUN U V W OUTPUT TB2 1 PLA 8 6 6 2 L N E MAINS INPUT TB1 9,11 10,12 10,12 9,11 CD-7287 ISSUE 1 Figure 2 - Drive Control Unit (GTX-A24): Main Assemblies Page 7.
KH1264 Chapter 7 PL2 - Drive Control Unit (GTX-A24): Parts List ITEM NUMBER DESCRIPTION KELVIN HUGHES Part No. 1 INVERTER PT No.
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KH1264 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 2 Page 1
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