SHIP'S TECHNICAL MANUAL

INSTALLATION, COMMISSIONING and MAINTENANCE INFORMATION for Mk V TRANSCEIVERS (CAE-A30-20 & CAE-A30-21)

PUBLICATION KH1207 Issue 3 February 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. 1030135 VAT No: GB 918080917/000

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

COPYRIGHT 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 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. 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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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: technical.advice@kelvinhughes.co.uk 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: training.department@kelvinhughes.co.uk 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: spares@kelvinhughes.co.uk 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: contract.support@kelvinhughes.co.uk

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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

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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. Whenever practical, before carrying out installation, maintenance or repair, personnel involved must: (1) (2) (3) Isolate the equipment from the electrical supply. Make tests to verify that the isolation is complete. 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

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4 5

This equipment contains materials which produce toxic fumes when ignited.

The inhalation of dust and fumes or any contact with lubricants when cleaning the equipment may be temporarily harmful to health, depending on individual allergic reactions. Components 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 abrasions. It is prudent to regard all damaged components as being potentially toxic, requiring careful handling and appropriate disposal.

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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 exposing 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, ensure that it is brought to the attention of someone in authority at deck or at ground level and that suitably 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 slippery ladder rungs and working areas. 9 When working on or near a radar scanner 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 example, a suitable face visor, gloves and a body apron should be worn when handling cathode ray tubes, as a precaution against injury in the event of breakage. EQUIPMENT SAFETY 11 12 Do not run the radar with the rotating joint output disconnected. 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 avoid damage to CMOS circuitry when any board is removed. 14 The equipment should be serviced by qualified agents only.

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ELECTRIC SHOCK RESUSCITATION 1 2 3

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

REMOVE CASUALTY FROM DANGER.

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.

REMOVE ANY OBVIOUS OBSTRUCTION TO BREATHING.

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)

WHEN NORMAL BREATHING COMMENCES, PLACE CASUALTY IN RECOVERY POSITION

OPEN AIRWAY, PINCH THE NOSE & HOLD THE CHIN. TAKE NORMAL BREATH, SEAL MOUTH, BLOW STEADILY (WATCHING CHEST RISE). REMOVE MOUTH, CHECK THAT CHEST FALLS, REPEAT RESCUE BREATH.

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

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

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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.
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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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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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KH1207 Chapter 1

CHAPTER 1 GENERAL DESCRIPTION

CONTENTS
Paragraph 1 7 10 INTRODUCTION SYSTEM DESCRIPTION Functional Description Page 1.3 1.4 1.4

ILLUSTRATIONS
Figure 1 2 System Block Diagram X-Band Upmast Configuration with CAN Bus Interface Page 1.6 1.7

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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: (1) (2) 2 Low Speed Antenna rotation - 24 rpm (CAE-A30-20). This configuration is used for normal applications. High Speed Antenna rotation - 40 rpm (CAE-A30-21). This configuration is used for high speed craft.

The following antennas can be used: (1) (2) (3) 1.3 m X-band Low Profile Antenna (LPA-A13) 1.9 m X-band Low Profile Antenna (LPA-A19) 2.5 m X-band Low Profile Antenna (LPA-A25)

The transceiver can be interfaced to the display system as follows: (1) (2) Parallel interface, where the display is connected directly to the transceiver. 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. 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.

(2)

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

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KH1207 Chapter 1 SYSTEM DESCRIPTION 6 The MkV Transceiver (CAE-A30-20 and CAE-A30-21) comprises the following main units: (1) (2) (3) (4) (5) (6) 7 8 Terminals PCB (CTX-A368) Modulator (CTX-A332) Magnetron/RF Head Receiver (CTX-A356) Azimuth PCB (CAE-A402/3) Tx Monitor (optional) (CTX-A198)

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

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

(2)

The Safety Switch must be set to OFF before removing the cover.
Functional Description 9 10 Figure 1 provides a block diagram of the transceiver.

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

18

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 21 The transceiver provides one SYNC and one VIDEO coaxial output. The two versions of transceiver use the following motor drives to rotate the antenna: (1) (2) 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). 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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Page 1.6
Tx MONITOR CTX-A198 (OPTIONAL) ANTENNA

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UPMAST TRANCEIVER CAE-A30-20, CAE-A30-21

AZIMUTH PCB CAE-A402/3 GEARBOX MOTOR OR

BRUSHLESS MOTOR PCB CAE-A236

THIS ITEM FOR CAE-A30-8 & CAE-A30-20 ONLY (40RPM)

MOTOR START PCB CTX-A359

TURNING MECHANISM
+26V MOTOR SUPPLY FROM DISPLAY VIDEO RECEIVER CTX-A356 IF RF HEAD MAGNETRON

THIS ITEM FOR CAE-A30-7 & CAE-A30-21 ONLY (24RPM)

PARALLEL INTERFACE TO/FROM DISPLAY OR INTERSWITCH UNIT

PARALLEL INTERFACE PARALLEL INTERFACE

+26V/+40V MOTOR SUPPLIES TRANSMITTER INTERFACE UNIT NNR-A66 (LOCATED DOWNMAST) USED WHEN CANBUS INTERFACE TO DISPLAY REQUIRED

Figure 1 - System Block Diagram

OR
TERMINALS PCB CTX-A368 POWER MODULATOR CTX-A332 RF POWER 40V PSU CZZ-A22 (LOCATED DOWNMAST) USED FOR HIGH SPEED MOTOR WHEN TIU NOT INSTALLED +40V MOTOR SUPPLIES

CANBUS INTERFACE TO/FROM DISPLAY OR INTERSWITCH UNIT

CANBUS INTERFACE

MAINS INPUT

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KH1207 Chapter 1

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

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KH1207 Chapter 2

CHAPTER 2 SPECIFICATION
CONTENTS

Paragraph 1 TECHNICAL SPECIFICATIONS Frequency RF Pulse Length and PRF Sync Output Receiver Operating Temperature and Humidity Turning Mechanism Data Input Power Requirement (Including Motor Supply)

Page 2.3 2.3 2.3 2.3 2.4 2.4 2.4 2.4

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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 Peak Power Output Magnetron Life RF Pulse Length and PRF PULSE LENGTH
SHORT (S) MEDIUM (M) LONG (L) VERY LONG (VL)

9410 30MHz 10kW 10,000Hrs (Typically)

PULSE WIDTH (nominal)

55 ns 210 ns 610 ns 610 ns

PRF (nominal)
3000 pps 1500 pps 750 pps 375 pps

Sync Output 1 x 75W, not less than +12V amplitude. Pulse to Pulse Jitter This will normally be activated and gives a maximum of 15 ms from the nominal period. This function can be inhibited.

An RS232 link is available for test purposes.

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KH1207 Chapter 2 Receiver Type Log-law RF input dynamic range IF Video output Peak video output level System overall noise figure Logarithmic Receiver Nominal 50 mV/dB (20 dB/V) 0 dBm to -90 dBm typical 60 MHz 1 x 75W 0.5 V to +5.0 V nominal 7.0 dB max

Operating Temperature and Humidity Ambient Temperature Range Humidity Turning Mechanism Data Azimuth Data Heading Data 90 pulses per revolution, +20 V amplitude nominal 1 pulse per revolution +20 V amplitude nominal -25C to +70C 95% at +40C

Input Power Requirement (Including Motor Supply) 24 RPM system 40 RPM system 170 W, 220 VA 230 W, 330 VA

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KH1207 Chapter 3

CHAPTER 3 TECHNICAL DESCRIPTION

CONTENTS
Paragraph 1 10 10 12 24 26 26 29 30 34 35 38 39 40 41 PHYSICAL DESCRIPTION FUNCTIONAL DESCRIPTION TRANSCEIVER TERMINALS 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 Page 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 MkV Transceiver: Module Locations Transceiver (CAE-A30-20 and CAE-A30-21): Block Diagram Transceiver (CAE-A30-20 and CAE-A30-21): Interconnection Diagram Page 3.4 3.11/12 3.13/14

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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 3 Figure 1 shows the mechanical arrangement of the transceiver. The MkV Transceiver (CAE-A30-20 and CAE-A30-21) comprises the following main units: (1) An Electronics Unit, with the following mounted on it: (a) (b) (c) (d) (e) (f) (2) Transceiver Terminals PCB (CTX-A368) Modulator (CTX-A332) Logarithmic Receiver (CTX-A356) Azimuth/Heading Line PCB (CAE-A402/3) Magnetron/RF Head 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) Antenna Motor Gearbox RF Rotating Joint, with Optional Tx Monitor PCB Mount for the antenna

(b) (c) (d) (e) 4

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

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

(2)

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 AZIMUTH PCB CAE-A402-3 AZIMUTH PCB LOCKING SCREW & CALIBRATION GUIDE Rx MONITOR CAVITY CTX-A173 (OPTIONAL)

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

MOTOR STARTER PCB CTX-A359 or MOTOR DRIVE PCB CAE-A236 (AT BACK OF CASTING) SAFETY SWITCH LOCATED ON UNDERSIDE OF CASTING

TERMINALS PCB CTX-A368

DISCONNECT ELECTRICAL PLUGS MODULATOR PCB CTX-A332 & MAGNETRON CTX-A197 (BENEATH COVER) Tx MONITOR PCB CTX-A198 (UNDERNEATH) ANTENNA MOTOR TERMINAL BLOCK TB2 TRANSCEIVER UNIT SHOWN WITH FRONT COVER REMOVED

M5 CHASSIS RETAINING BOLTS

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Figure 1 - MkV Transceiver: Module Locations

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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. The Modulator provides the following: (1) (2) (3) (4) (5) Low voltage supply (+14 V, +5 V, -7 V) generation from the +27 V input. +350 V power supply generation from the +27 V input. This supply used to provide the pulses to the magnetron. Driver circuits for the pulse transformer. Sync pulse circuit. 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.

10

11

The following inputs are applied to the FET modulator: (1) (2) Pulse Length, Run and Mute from the display. External Trigger (not used in this application).

12

The following signals are output from the FET modulator: (1) (2) (3) Tx Ready to the display. Sync Pulse to the display. Magnetron Drive pulse to the magnetron. Page 3.5

Issue 3

KH1207 Chapter 3 13 The modulator board requires the following power supplies from the Display: (1) (2) 14 +27 V at 1.5 A. +8.5 V at 550 mA (Magnetron Heater supply).

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 reads 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, indicating 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 18 The microcontroller sets the pulse width for the magnetron pulses, depending on the p.r.f.

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 The RF Head comprises: (1) (2) (3) (4) (5) (6) 21 A 10 kW Magnetron RF Filter Ferrite Circulator PIN Diode Driver and Limiter Slotted filter shim Low Noise Front End (LNFE)

The Low Noise Front End combines an RF amplifier, balanced mixer, electronically tuned local oscillator and IF head amplifier. Issue 3

Page 3.6

KH1207 Chapter 3 Signal Paths High Power 22 Typical RF pulse conditions for the 10kW magnetron are: (1) (2) (3) (4) 23 Short Pulse: 50 to 70 ns at 4.0 A Medium Pulse: 200 to 260 ns at 4.5 to 5.5 A Long Pulse: 580 to 650 ns at 4.5 to 5.5 A Very Long Pulse: 580 to 650 ns at 4.5 to 5.5 A

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

27

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

Issue 3

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. 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.

(2)

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 rotated 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 MOTOR 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-BAND ANTENNA LAP-A13, LPA-A19, LPA-A25

PL1

+36V/40V

PL3

BRUSHLESS MOTOR DRIVER CAE-A236 TB2 DC SUPPLY TO ANTENNA MOTOR

HIGH SPEED MOTOR

MONITOR ARM PART OF CAE-A198 (OPTIONAL) Tx MON NEON

PL2

HIGH SPEED MOTOR CAE-A30-21

GEARBOX ROTATING JOINT

PL5

AZ/HL PCB CAE-A406-3 LOCATION 5

+26V PLA SAFETY SWITCH START RUN +26V MOTOR STARTER CTX-A359 PLB

FILTER

LOW SPEED MOTOR

LOW SPEED MOTOR CAE-A30-20

PLM Rx MONITOR CAVITY CTX-A173 LOCATION 8 (OPTION)

PLL

FLYING LEAD Tx MON PCB CTX-A198 LOCATION 7 (OPTION) PLB

10kW MODULATOR CTX-A332 LOCATION 4

Gn

PLN

TERMINALS PCB CTX-A368 LOCATION 2 PLE

DC SUPPLIES MOD SYNC Tx READY

PLA

HIGH VOLTAGE POWER SUPPLY UNIT

400V

MAGNETRON DRIVER FET DRIVE

Y BRAID

MAGNETRON CTX-A197

TRIGGER MUTE RUN LP/MP LPRE PULSE SECTOR MUTE PCB CTX-A162 LOCATION 6

PLA

CONTROL CIRCUITS D53 RUNNING

MOD TRIG

MOSFET DRIVER PCB CTX-A339

LOW PASS FILTER 45-750-0015-001 PL1

CIRCULATOR 45-646-604 PIN DIODE DRIVE AND LIMITER CTX-A512 FILTER SHIM NTX-1194

PLH

PLH

LOGARITHMIC RECEIVER CTX-A364/CTX-A356 LOCATION 3

MAG HEATER MUTE -12V/-15V RUN Tx READY TUNE CONT. MP/LP TUNE LED HEADING LINE VIDEO SYNC MOD +27V AZIMUTH Rx MON

PLE

+5V & TUNE

SKC SKB SKA

60MHz IF Rx TRIG TUNE PULSE LENGTH TUNE IND +15V PLD PLC

LOG AMP CONTROL CIRCUITS

PLG

PULSE WIDTH

38 CORE MULTICORE FROM DISPLAY INTERSWITCH UNIT or TIU

BANDPASS FILTER

LOG AMP PLF Tx MON PULSE PLC PLD VIDEO OUTPUT (COAX) AZIMUTH/HEADING LINE OUTPUT CIRCUITS

SKA

LOW NOISE FRONT END (LNFE) CTX-A515

PLK

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

CD-6920

ISSUE 2

Figure 2

PLA

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

PLA

Figure 2

Issue 3

Page 3.11/12

KH1207 Chapter 3
TERMINALS PCB CTX-A368 (PART OF)
LOCATION 2 0V HL AZ +27V AZ TEST AZ TEST SKM 1 +27V MOD 2 +27V SW 3 4 2PLE MOD +27V MOD 0V N/C MAG HTR +8V MAG HTR 0V 0V (SIG) RUN Tx READY MP LP SYNC (SCRN) Rx SYNC 0V SECTOR MUTE MOTOR FLY-LEAD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2PLA 1 2 3 4 5 6

AZ/HL PCB CAE-A402/3

LOCATION 5 4 SOLDER PIN 3 2 1 5 6

FILTER
TB2 1 2 3 4 5 6 7 8 +26V

MOTOR

PLA 0V

+26V MOTOR STARTER PCB CTX-A359

1 2 3 +27V MOTOR START +26V MOTOR START 0V +26V SWITCHED RETURN

SAFETY SWITCH PLB 1 2

MODULATOR CTX-A332
4PLB 5 2 4 1 3 LOCATION 4 MOD +27V 0V (Rx SYNC) MAG HTR +8V Tx READY Rx SYNC

PART OF 38 CORE TO DISPLAY OR INTERSWITCH UNIT

LOW SPEED MOTOR CONNECTIONS CAE-A30-20

SAFETY SWITCH TB2 1 2 3 4 5 6 7 8 +40V +40V 0V 0V PL1 1 2 3 4 PL4 1 2 3 4 5 6 RPM/10 +40V SHUTDOWN IND OVERTEMP BOARD GND +5V SOURCE

+40V +40V 0V 0V

BRUSHLESS MOTOR DRIVER PCB CAE-A236 RUN+

SKM 1 2 3 4 RUN (V) RUN (SW) AE STARTER AE 0V

PL5

2 RUN- 1 PL3 L1 1 L2 2 L3 3 PL2 +5V PS3 PS2 1 2 3 4 5 6 7 8 MOTOR FLY-LEAD

4PLA 1 4 5 10 8 9 3 7 6 2 MAG HTR 0V 0V (SIG) RUN MP LP SYNC (SCRN) EXT TRIG PRE PULSE SECTOR MUTE

BRUSHLESS MOTOR UNIT

Y GN

MAGNETRON CTX-A197 (10KW)

2PLL +27V Rx MON 1 2

(NOT EARTH) 0V PLANE PS1

Rx MONITOR CAVITY CTX-A173 (OPTION)

LOCATION 8

CIRCULATOR

HIGH SPEED MOTOR CONNECTIONS CAE-A30-21

2PLK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2PLG 1 2 3 4 5 6 7 8 9 10 11 12 2PLF 1 2 3 4 SCREEN SYNC VIDEO SCREEN 2PLC VIDEO SCR VIDEO OUT 1 2 3 MAG HTR +8V MAG HTR 0V MUTE -12V/15V 0V (SIG) RUN Tx READY TUNE CONT TUNE LED MP LP HL 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

PIN DIODE DRIVER & LIMITER PL1 CTX-A512

1 2 3 4 INHIBIT 0V Rx TRIG +15V

RECEIVER CTX-A356
2PLD -12V 5 Rx SYNC 14 LP 1 SP 6 +15V 3 +27V 4 Tx MON PULSE 7 0V 2 TUNE LED 10 0V (SIG) 13 3PLC 5 14 1 6 3 4 7 2 10 13 8 9 11 12 LOCATION 3 0V -12V VCO TUNE Rx SYNC LP SP +15V +27V Tx MON PULSE 0V TUNE LED 0V (SIG) NOISE SW IND IND 1 NOISE MONITOR MON OUT 3PLE 1 2 3 4 3SKA

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

2 CORE Tx MON ARM

PART OF 38 CORE TO DISPLAY OR INTERSWITCH UNIT

3PLB 2 1 3PLD

TUNE CONT 12

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

1 2 3 4 5 6

SECTOR MUTE PCB CTX-A162

LOCATION 6 +15V 0V HL AZ SECTOR MUTE 6SKH 1 2 3 4 5 6 2PLH 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

2PLN +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

CD-6551

ISSUE 2

Figure 3

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

Figure 3

Issue 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 32 33 35 36 37 44 45 GENERAL COMPASS SAFE DISTANCES TRANSCEIVERS SAFETY NOTES EQUIPMENT LOCATION TRANSCEIVER/TURNING MECHANISM OPTIONAL MAINS ISOLATOR (80-261-600) INSTALLATION TRANSCEIVER AND TURNING MECHANISM Fitting the Transceiver/Turning Mechanism to the Ship Fitting the Low Profile Antenna Fitting the Monitor Arm OPTIONAL MAINS ISOLATOR (80-261-600) ELECTRICAL CONNECTIONS CABLE SPECIFICATIONS 38-Core Custom Built Cable 12-Core Composite Cable 14 Core Composite Cable Small Multi-Core Cables Power Cables 2-Core (Power): Co-axial Cable Co-axial Cable 75 ohms low loss (for extended cable runs) TRANSCEIVER PCB Locations and Cableform Routing Checks after Fitting 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 4.17 4.18 4.18 4.18 4.19 4.19 4.20 4.21 4.21

TABLES
Table 1 2 3 CABLE SPECIFICATION 38-CORE CABLE COLOUR ABBREVIATIONS 14-CORE CABLE COLOUR ABBREVIATIONS Page 4.15 4.16 4.17

Issue 3

Page 4.1

KH1207 Chapter 4 CONTENTS (continued) LIST OF ILLUSTRATIONS

Figure 1 2 3 3 4 5 6 7 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 4.9 4.10 4.11 4.12 4.13 4.14 4.23/24 4.25

Page 4.2

Issue 3

KH1207 Chapter 4

CHAPTER 4 INSTALLATION
GENERAL 1 2 This section provides installation information for MkV Upmast X-Band Transceivers.

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 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) (2) 6 Low Speed Transceiver/Turning Mechanism CAE-A30-20. High Speed Transceiver/Turning Mechanism CAE-A30-21. 3.0 m 0.2 m Grade II (1 degree) 1.8 m 0.1 m

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

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. The Transceiver Unit must be hoisted to the fixing position using a secured block and tackle or rope strops. Safety personnel must ensure that persons do not encroach on the area of work. The Antenna and Transceiver Unit MUST NOT be lifted by the array, but secured and hoisted evenly.

12

13 14

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 ships head) and the vertical radiated beam clearing the ships bow. 16 The primary consideration must be the strength of the support for the 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. 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, crosstrees and other large areas can reflect energy and give rise to spurious echo returns especially in close proximity to land. Positioning the antenna close to funnels and exhaust gasses can adversely affect antenna performance. The transceiver/turning mechanism must not be mounted where the temperature exceeds 70C. 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 ships flexible communication aerials to avoid damage to both.

(2)

(3) (4)

NOTE: A heavy duty earthing strap or cable must be taken from the transceiver/turning mechanism to the ships 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 are 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 separate 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 VICINITY 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) (2) (3) The transceiver/turning mechanism is fitted with a Low Profile Antenna. For transceivers mounted in excess of 1.8 m above the deck, it is recommended that a service platform and guard rail are fitted. 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) Any chipped or damaged surfaces must be painted with polyurethane paint.

Page 4.6

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) (2) Hoist the Transceiver/Turning Mechanism to the mounting plate. 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 ships superstructure using a copper earthing strap connected to the earthing point shown in Figure 1. 23 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.

Issue 3

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) (2) Remove the protective caps, tapes etc. 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 supplied in the fitting kit, LPA-A165. Apply Loctite to all screws. 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. Waterproof the waveguide joint by sealing with a layer of greased plastic compound such as Henleys compound or Denso-Tape. Finally tighten fasteners holding swing casting to antenna to a torque of 29 Nm.

(3)

(4) (5)

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 cable gland and clamped. The cable screen is to be earthed by the ferrules in the cable gland assembly.

Page 4.8

Issue 3

562

290

Issue 3
PTFE WINDOW FITTED AT THIS CONNECTION 85 192 2509 1908 1308

MONITOR ARM

FWD
CABLE ENTRY (AT REAR) 18mm OFF CENTRE 34mm FROM BASE

FIXING BOLTS 3 x M12 EARTHING STRAP 380 CABLE ENTRY (DIAMETER OF CABLE GLAND - 22mm) 145 290 325

ALL DIMENSIONS IN MILLIMETRES UNLESS OTHERWISE STATED 290

NOT TO SCALE

TRANSCEIVER ANTENNA(1.3m) ANTENNA(1.9m) ANTENNA(2.5m) MOUNTING BOLT 'FOOTPRINT'

WEIGHT: 22kg WEIGHT: 5kg WEIGHT: 7.5kg WEIGHT: 10kg

POWER CONSUMPTION: LOW SPEED 170W HIGH SPEED 230W 14 mm

DANGER HIGH VOLTAGE

OPERATING TEMPERATURE RANGE

OPERATING TEMPERATURE: -25 C to +70 C RELATIVE HUMIDITY: +40 C

ANTENNA ARRAY 1. FIT O RING IN ANTENNA FEED, THEN ASSEMBLE ANTENNA ARRAY TO TRANSCEIVER USING 6 x M6 BOLTS, NUTS AND WASHERS PROVIDED. SEE FIGURE 3. POSITION OF SAFETY SWITCH

OFF ON

2. ASSEMBLE ANTENNA FEED TO ROTATING JOINT WITH "O" RING SEAL. USE BOLTS, NUTS AND WASHERS PROVIDED.

Figure 1 - Transceiver Fixing Centres and Outline Dimensions

INTERIOR ACCESS 4. ACCESS TO THE TRANSCEIVER INTERIOR OBTAINED BY UNSCREWING THE FOUR CAPTIVE M8 BOLTS.

CABLE ENTRY 5. PASS THE CABLE THROUGH THE REAR OF THE CABLE GLANDS, USE SPANNER PROVIDED TO TIGHTEN GLAND NUT. DO NOT OVERTIGHTEN.

BEFORE ANY MAINTENANCE IS CARRIED OUT TO THE TRANSCEIVER INTERNALS, SWITCH OFF ANTENNA ROTATION AND +27V AT THE EXTERNAL SAFETY SWITCH

KH1207 Chapter 4

Page 4.9

CD-3730

ISSUE 3

KH1207 Chapter 4

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

FWD

MOUNTING PLATE 12mm MINIMUM THICKNESS

450 290

45

STEEL TUBE WALL THICKNESS 12mm MINIMUM DIAMETER 150mm MINIMUM

410

290

14 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 SHIPS RESPONSIBILITY 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 THIRD ANGLE PROJECTION

LPA-1097
USED ON

SEE NOTE 2

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

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
TOLERANCES UNLESS
OTHERWISE STATED
SCREW THREADS COARSE PITCH INTERNAL EXTERNAL HOLES TO BS 4500 DIMENSIONAL TWO DECIMAL PLACES 0.15 ONE DECIMAL PLACE 0.5 NO DECIMAL PLACE 1.0 ANGULAR 1 BS 3643 CLASS 6H CLASS 6g CLASS H13

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

MATERIAL

M/C

ALL DIMENSIONS IN

SCALE

SIMILAR TO

DEA/A3_FORMAT_ISS.3

MILLIMETRES (UNLESS OTHERWISE STATED)

NTS

CODE No.

FINISH
1
ISS DATE C/NOTE SIG. ISS

TITLE

14-06-04 DR0458
DATE C/NOTE

NRD
SIG.

LPA RECOMMENDED LIFTING TECHNIQUE

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 supplied).

80 160

30

160 205

120

WIRING FOR 3 PHASE

WIRING FOR SINGLE PHASE

CABLE 211K 15mm 1.D CABLE GLAND

15mm 1.D CABLE GLAND

L1

L2

L3

L1

L2

L3

L1

L2

L3

L1

L2

L3

CONNECT SCREENS TO EARTH

FIT 20 AMP FUSES

15mm 1.D CABLE GLAND

FIT 20 AMP FUSES SHIP'S SUPPLY SINGLE PHASE 110V/220V

15mm 1.D CABLE GLAND

CD-1157

Figure 5 - Optional Mains Isolator: Installation Dimensions

Page 4.14

Issue 3

KH1207 Chapter 4 ELECTRICAL CONNECTIONS CABLE SPECIFICATIONS 28 Each cable is identified by a letter code which defines the type of cable required, e.g. Cable code N is a 38-core cable. Table 1 provides specifications for each cable type. Table 2 provides 38-core cable, colour code abbreviations. 29 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. TABLE 1 - CABLE SPECIFICATION CABLE
E H I K N P

DESCRIPTION
12-core small multi-core 14-core composite 2 x 1.5 mm Power (low) 2-core Power 38-core small multi-core Co-axial (Low Loss) Type ECL 125

CODE
1344-722 45-762-0116-001 45-762-0173-001 1344-1123 5344-701 5344-719 (for long cable lengths only) 45-762-0041-001

CORE
16/0.2 Mixed 1.5 mm 1.5 mm 1.5 mm Varies

DIAMETER
10 mm 11 mm 18 mm 8 mm 12 mm 17 mm 8.3 mm

12 core small composite

Mixed

15.4 mm

38-Core Custom Built Cable 30 The 38-core composite cable (KH code number 5344-701) is made for Kelvin Hughes and comprises the following: (1) (2) (3) 4 cores of 32/0.2 mm copper wire. 32 cores of 16/0.2 mm copper wire. 2 cores of co-axial cable.

12-Core Composite Cable 31 The 12-core composite cable (KH code number 45-762-0041-001) is made for Kelvin Hughes and comprises the following: (1) (2) (3) (4) 4 cores of 32/0.2 mm copper wire. 4 cores of 16/0.2 mm copper wire. 2 cores of 16/0.2 mm twisted and screened. 2 cores of co-axial cable.

Issue 3

Page 4.15

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

R B G Y W Bk Bn V O P T or Lt/G S R/B R/G R/Y R/W R/Bk R/Bn B/Y B/W B/Bk B/O G/Y G/W G/Bk G/O G/S Bn/Bk Bn/Y Bn/W S/B S/Bn V/Bk V/Y V/W G/B RED BLUE GREEN YELLOW WHITE BLACK BROWN VIOLET ORANGE PINK TURQUOISE or LIGHT GREEN SLATE (grey) RED/BLUE RED/GREEN RED/YELLOW RED/WHITE RED/BLACK RED/BROWN BLUE/YELLOW BLUE/WHITE BLUE/BLACK BLUE/ORANGE GREEN/YELLOW GREEN/WHITE GREEN/BLACK GREEN/ORANGE GREEN/SLATE BROWN/BLACK BROWN/YELLOW BROWN/WHITE SLATE/BLUE SLATE/BROWN VIOLET/BLACK VIOLET/YELLOW VIOLET/WHITE GREEN/BLUE WHITE CO-AX SLATE CO-AX N/C NO CONNECTION

COLOUR

Page 4.16

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: 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). (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: 1.0 mm2 100 V 100 mA 0.5 mm2 30 V 50 mA Coaxial 15 V 75 W <3 dB at 25 MHz up to 60 m

DC between conductors DC current Impedance Losses

TABLE 3: 14-CORE CABLE COLOUR ABBREVIATIONS ABBREVIATION

R B G Y BN V O W S RED BLUE GREEN YELLOW BROWN VIOLET ORANGE WHITE SLATE (GREY)

COLOUR

Issue 3

Page 4.17

KH1207 Chapter 4 Small Multi-Core Cables 33 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. 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 = 0.40 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 cables are used for services requiring a moderate current carrying capacity, i.e. mains supplies.

34

2-Core (Power): Cable Code K: 250/440V grade: KH Reference No. 1344-1123 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 12 mm

Outer diameter:

Page 4.18

Issue 3

KH1207 Chapter 4 Co-axial Cable 36 Where the distance between the Display and the Transceiver exceeds 60 metres, special co-axial cables and/or Sync and signal amplifiers may be required to obtain optimum results, consult Kelvin 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: Electrical Attenuation: Attenuation: Attenuation: Impedance: 60MHz 3.4dB/100m MAX 100MHz 4.9dB/100m MAX 200MHz 7.1dB/100m MAX 75 Ohm CODE No. 5344-719 Type ECL 125 (Manufacturers code) 1.25 mm Single Conductor Air spaced Polyethylene Tape Screen 8.3 mm

Issue 3

Page 4.19

KH1207 Chapter 4 TRANSCEIVER 37 Before starting electrical connection observe the following: WARNING ENSURE THAT ALL POWER SUPPLIES ARE ISOLATED BEFORE ANY ELECTRICAL CONNECTION TAKES PLACE. (1) (2) (3) 38 Ensure that the associated display is turned off. Remove fuses from mains isolators. 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) (2) (3) (4) 41 Upmast Transceiver. Optional Mains Isolator. Transmitter Interface Unit (if fitted). 40V Power Supply (if fitted).

To access the transceiver, remove the four captive screws securing the rear cover to the Upmast Transceiver and remove the cover. To access the optional mains isolator, remove the cover by releasing the captive screw. Ensure that all cables are secured to their associated entry point and that screened cables are earthed to their respective units.

42 43

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: (1) (2) (3) (4) (5) Remove gland nut, plastic washer and seal and discard washer. Thread cable through back of gland housing for approx. 300 mm. Remove cable outer covering (exposing braid) back as far as 15 mm from the gland housing. Fold braid double to 80 mm from gland housing (remove excess). 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. Place seal over cable and onto outer covering at the gland housing. 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. Connect wires as shown in Figure 7. The fitting kit contains Densotape, which is used to seal the cable entries.

(6) (7)

(8) NOTE:

Checks after Fitting 45 The upmast transceiver must be checked for security and for freedom of the antenna to rotate. Ensure that all cables are secured to their associated entry point and that screened cables are earthed to their respective units. All cable entries must be checked for signs of fretting, chafing or damage, and subsequently sealed with a mastic compound. Commissioning instructions are described in Chapter 5.

46

47

48

Issue 3

Page 4.21

KH1207 Chapter 4

THIS PAGE INTENTIONALLY BLANK

Page 4.22

Issue 3

KH1207 Chapter 4

8
1. REMOVE GLAND NUT, PLASTIC WASHER AND SEAL AND DISCARD WASHER. 2. THREAD CABLE (1N) THROUGH BACK OF GLAND HOUSING FOR APPROX 300mm. 3. REMOVE CABLE OUTER COVERING (EXPOSING BRAID) BACK AS FAR AS 15mm FROM THE GLAND HOUSING. 4. FOLD BRAID DOUBLE TO 80mm FROM GLAND HOUSING (REMOVE EXCESS). 5. PLACE SEAL OVER CABLE AND ONTO OUTER COVERING AT THE GLAND HOUSING. 6. INSERT THE TWO SCREENING FERRULES (10) BETWEEN OUTER COVERING AND SCREEN BRAID AT GLAND AS SHOWN. 7. PLACE 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.

TB2

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

TB2

Casting Gland Rubber Seal Ferrule

ITEM PACK QTY 2 1 14 PART No.

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

45-718-5144

12

45-718-5143

45-718-5163

CDY-4031

CDY-A425

20-233-1101-27

20-282-5006-25

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

FWD

22

30-762-502-00

45-716-6027

Tx Monitor Arm

10

CAE-4054

THREE M12 FIXING BOLTS (SUPPLIED AS PART OF FITTING KIT)

Safety Switch
CD-3731 Before any maintenance is carried out on the transceiver, isolate mains supply via external safety switch.

SAFETY SWITCH. BEFORE ANY MAINTENANCE IS CARRIED OUT TO TRANSCEIVER, ISOLATE MAINS SUPPLY VIA EXTERNAL SAFETY SWITCH.

Figure 6

38-Core Composite Cable: Installation

Figure 6

Issue 3

Page 4.23/24

Issue 3
TIU NNR-A66-ABAB
CAN ADAPTER PCB NNR-A981 PLF
VIDEO SKF SYNC SKH

Mk V CAE-A30-20 & CAE-A30-21

WHITE COAX WHITE COAX 4 3 VIDEO

COAXES W
SYNC SKG VIDEO SKE

GREY COAX GREY COAX 2 1 SYNC PLG PLB

S PLA W S
1 CAN HI 2 CAN LO

SCR
SCREEN NOT TERMINATED

S R/G B/Y B/W R/Y R/W T G/O B/Bk G/W R/B 38-CORE CUSTOM CABLE N PLK

TO PROCESSOR or INTERSWITCH

14-CORE

CUSTOM CABLE H

RUN MUTE MP LP TUNE TUNE IND TX READY AZ N/C RX MON HL N/C N/C GND W Bk R/G Bn/Bk R/B S T R/Y R/W B/Y B/W G/W 1 2 3 4 5 6 7 8 9 10 11 12 HEATERS +ve HEATERS -ve MUTE -15V 0V RUN TX READY TUNE TUNE IND MP LP HEADING LINE

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

SCREEN NOT TERMINATED

AZIMUTH CONVERTER CTX-A523 PL2

+15V -15V HEATERS +ve HEATERS -ve MODULATOR +27V

TERMINALS PCB NNR-A1004 PLB

SCR

R B O R/Bn P V/Bk R/Bk G/O 1 2 3 4 5 6 7 9 12 13

+27V 0V +27V +27V 0V 0V +15V AZIMUTH TX MON TX MON RTN 14 RX MON TB2 1 2 SCANNER +VE 3 4 5 6 SCANNER -VE 7

R B

MONITOR ARM

Bn Bn/W V V/W O B/O AZ1 nAZ1 AZ2 nAZ2 HL nHL B/Bk

MODULATOR 0V

1 2 3 4 5 6 7 8
PLC

1 2 3 4 5 6 7 8 9 10

R/Bk Bn/Bk W Bk R O R/Bn B P V/Bk

MAINS PSU 45-690-0041-001

SCANNER +ve

Figure 7 - Transceiver Connection Diagram

Y G
SCR FILTER R B SCR L N E
SCANNER -ve

PLB 1 PSU ON 2 PSU ON RTN 3 4

G W/V Bn S/Bn Y/Bn W/Bn S/B S/G Y B/O V G/Y G/B G/Bk SCR

50/60Hz, 110V/220V/1 PHASE

2-CORE POWER

CABLE I

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

G W/V Bn S/Bn Y/Bn W/Bn S/B S/G Y B/O V G/Y G/B G/Bk SCR

Mk 5 X-Band Upmast Connections

KELVIN HUGHES

Page 4.25

KH1207 Chapter 4

EHD-0132

S.R.

04.07.08

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 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 Adjustment) To Correct an Error (Coarse Adjustment) PERFORMANCE MONITORING CHECKS Page 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 MkV with TIU: System Heater Circuit Transceiver Electronic Module Performance Monitor Display Page 5.6 5.10 5.11

Issue 3

Page 5.1

KH1207 Chapter 5

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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 3 4 The installer must carry out the following procedures to commission the equipment. Check that all cables have been installed and connected correctly. Interswitched equipments, or equipments interfaced with other radar equipments, are described in their respective Handbooks. 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.

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

Issue 3

Page 5.3

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

LK4 LK5

LK6 LK7 LK8 LK9

Page 5.4

Issue 3

KH1207 Chapter 5 SETTING TO WORK 7 For all systems, carry out the following: (1) (2) (3) (4) 8 Switch on the single phase mains at the Isolators for the Display and Transceiver. Set the display power switch to ON. If a 40V Power Supply is fitted set the ON/OFF switch on top of the unit to ON. If a TIU is fitted set the ON/OFF switch on the top of the unit to ON.

At the display ensure that the Transceiver is entered as MkV in the installed equipment parameters. 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) Set the TIU power supply switches SW1 CAE-A30-20 CAE-A30-21 (2) (3) (4) (5) ON (9.9V) ON (9.9V) SW2 ON (26V) OFF (36V) Low speed High speed

To measure the heater current connect an ammeter in series with wire from the TIU Terminals PCB (NNR-A1004) pin 3. Switch the system ON. KEEP AT STANDBY ONLY. DO NOT SWITCH TO RUN. The Heater Current is to be between 0.56A and 0.6A. 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). Switch the system ON. If the current is still low, switch the system OFF and make link LK1 on the Transmitter Modulator PCB (CTX-A332).

(6) (7)

Issue 3

Page 5.5

KH1207 Chapter 5 (8) Switch the system ON. Once the heater current is correct, switch the system OFF.
Mk 5 TRANSCEIVER CAE-A30-7, -8, -20, -21
TERMINALS PCB CTX-A368 MODULATOR PCB CTX-A332
(NORMALLY OPEN)

TRANSMITTER INTERFACE UNIT NNR-A66

POWER SUPPLY UNIT 45-677-124 TERMINALS PCB NNR-A1004 A +9.9V 0.4V 0V 1R0 LK1 B PLB-3 PLB-4 A +ve WIRE V DROP (0.5mm ) 22.6mV/METRE @ 0.58A -ve WIRE V DROP, VERY LOW DUE TO MULTI-PATH CONNECTIONS
2

LK1 +V PLG-1 0V PLG-2 FILTER INDUCTOR 1R0

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) (2) (3) (4) Check that the array/gearbox alignment mark is correct. Switch ON the Display and operate in a HEAD UP mode and at a range of 6 miles. 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.

To Correct an Error (Fine Adjustment) 15 Any error is present in the Heading Line may be adjusted as follows: (1) (2) (3) (4) (5) Switch the Gearbox Safety Switch to OFF. Switch all supplies to STANDBY. Remove the four captive screws securing the cover to the rear of the Turning Mechanism and remove the cover. Loosen the Azimuth/Heading Line PCB locking screws, refer to Figure 1. 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. (6) (7) (8) Remove the error by sliding the PCB by the number of degrees to correct the misalignment. Retighten the Azimuth/Heading Line PCB. Refit the outer cover.

Issue 3

Page 5.7

KH1207 Chapter 5 (9) (10) (11) (12) Set the Safety Switch to ON. Set the Display to RUN and check that the visual and PPI display bearing of the known target. To make any further adjustment repeat step (6). Secure the rear cover.

To Correct an Error (Coarse Adjustment) 16 The Heading Line Opto Disc is factory set, however if the fine adjustment does not achieve the required correction, proceed as follows: (1) (2) (3) (4) (5) (6) (7) (8) (9) Perform Paragraph 14, steps (1) to (3). Disconnect the plug to the Heading Line PCB. Remove the Heading Line PCB, ensuring that the opto sensor does not foul against the opto disc. With the array facing forward, check that the leading edge of the heading line disc recess is in line with the array centre line. 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. Manually rotate the disc to the new position required and retighten the bolts. Refit and reconnect the Heading Line PCB by sliding the opto device over the edge of the opto disc. Refit the retaining pillars and reconnect the plug. 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. The two specific types of optional performance monitors that can be fitted are: (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. Receiver Monitor - comprises a resonant cavity with an adjustable plunger, which is factory set according to magnetron frequency. It is fitted to 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.

18

(2)

19

To carry out the performance monitor check, proceed as follows (refer to Figure 3 for typical displays): (1) (2) (3) (4) (5) (6) Switch the display power to ON. After the Tx warm-up period, the screen should indicate TX READY, select GO TO RUN. Select 1.5 mile range and PERF.MON, (this should also be indicated - top left hand side of the Nucleus screen). Ensure that the picture is correctly tuned. By using the VRM facility, measure the diameter of the radar sun that appears in the centre of the display. 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. Select the 12 mile range. 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.

(7) (8)

Issue 3

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 CIRCULATOR ASSEMBLY 45-646-604 RF FILTER

PIN DIODE DRIVER PCB

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

DANGER

Tx MONITOR PCB (OPTION) UNDER CHASSIS

TRANSCEIVER TERMINALS PCB CTX-A368 CHASSIS RETAINING SCREWS

TB2

CD-3835

ISSUE 2

Figure 2 - Transceiver Electronic Module

Page 5.10

HIGH VOLTAGE

13kW

MODULATOR PCB COVER

Issue 3

KH1207 Chapter 5
340 330 320 310 300 350 000 010 020 030 040 050 060

290

070

280

080

270

090

260

100

250

110

240 230 220 210 200

CD-7555
ISSUE 1

120 130
140

150 190 180 170 160

Receiver Monitor
340 330 320 310 300 350 000 010 020 030 040 050 060

290

070

280

080

270

090

260

100

250

110

240 230 220 210 200 CD-7557

ISSUE 1

120 130 140 150 190 180 170 160

Transmitter Monitor

Figure 3 - Performance Monitor Display

Issue 3

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KH1207 Chapter 5

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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 INTRODUCTION PLANNED MAINTENANCE PERFORMANCE CHECKS - MONTHLY OR ON BEFORE LEAVING PORT SIX MONTHLY CHECKS Antenna Transceiver Casing Inspection Tx Monitor Arm Antenna Motor/Gearbox DIAGNOSTIC MAINTENANCE PRE-REQUISITES FAILURE MESSAGES PERFORMANCE CHECK DEGRADATION TEST EQUIPMENT PREPARATION FOR FAULT DIAGNOSIS TEST POINTS CORRECTIVE MAINTENANCE 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) Replacement of Transceiver Terminals PCB (CTX-A368) Removal of Modulator PCB Assembly (CTX-A332) Replacement of Modulator PCB Assembly (CTX-A332) Removal of Receiver PCB (CTX-A356) Replacement of Receiver PCB (CTX-A356) Removal of Azimuth PCB (CAE-A402/3) Replacement of Azimuth PCB (CAE-A402/3) Removal of Magnetron Assembly (CTX-A197) Replacement of Magnetron Assembly (CTX-A197) Removal of Circulator Assembly (45-646-604) Replacement of Circulator Assembly (45-646-604) Removal of PIN Diode Driver and Limiter (CTX-A512) Replacement of PIN Diode Driver and Limiter (CTX-A512) Removal of Low Noise Front End Assembly (CTX-A515) Replacement of Low Noise Front End Assembly (CTX-A515) Removal of Transmitter Monitor PCB (CTX-A198) Replacement of Transmitter Monitor PCB (CTX-A198) Removal of Sector Mute PCB (CTX-A162) Replacement of Sector Mute PCB (CTX-A162) Removal of Receiver Monitor Cavity (CTX-A173) Replacement of Receiver Monitor Cavity (CTX-A173) Removal of Monitor Arm (CAE-A147) Replacement of Monitor Arm (CAE-A147) Removal of Motor (Low Speed (CAE-A30-20)) Replacement 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

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KH1207 Chapter 6 CONTENTS (continued)

Para 55 56 57 58 59 60 61 62 63 65 66 67 68 69 70 71 Removal of Motor (High Speed (CAE-A30-21)) Replacement of Motor (High Speed (CAE-A30-21)) Removal of the Brushless Motor PCB (CAE-A236 (High Speed Motor)) Replacement of the Brushless Motor PCB (CAE-A236 (High Speed Motor)) Removal of +26V Motor Starter Assembly (CTX-A359 (Low Speed Motor)) Replacement of +26V Motor Starter Assembly (CTX-A359 (Low Speed Motor)) Removal of Rotating Joint Replacement of Rotating Joint CHECKS AFTER UNIT REPLACEMENT Modulator PCB Transceiver Terminals PCB Azimuth PCB Magnetron Assembly Low Noise Front End Diode Limiter Receiver Monitor Cavity Page 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 LOCATION OF PCBs AND MODULES LOCATION OF OPTIONAL PCBs AND MODULES Page 6.17 6.18

ILLUSTRATIONS
Figure 1 2 3 3 4 5 6 7 8 9 10 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 6.11 6.13 6.14 6.15 6.33 6.34 6.35 6.36 6.37/38 6.39 6.40

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KH1207 Chapter 6

CHAPTER 6 MAINTENANCE
INTRODUCTION 1 This Chapter is divided into three parts: (1) (2) (3) Planned Maintenance. Diagnostic Maintenance. 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. The two specific types of optional performance monitors that can be fitted are: (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. Receiver Monitor - comprises a resonant cavity with an adjustable plunger, which is factory set according to magnetron frequency. It is fitted to 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.

(2)

To carry out the performance monitor check, proceed as follows: (1) (2) (3) (4) Switch the display power to ON. After the Tx warm-up period, the screen should indicate TX READY, select GO TO RUN. Select 1.5 mile range and PERF.MON, (this should also be indicated - top left hand side of the Nucleus or Manta screen). Ensure that the picture is correctly tuned.

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KH1207 Chapter 6 (5) (6) By using the VRM facility, measure the diameter of the radar 'sun' that appears in the centre of the display. 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. Select the 12 mile range. 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. 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).
340 330 320 310 300 350 000 010 020 030 040 050 060

(7) (8)

(9)

290

070

280

080

270

090

260

100

250

110

240 230 220 210 200 CD-7555

ISSUE 1

120 130 140 150 190 180 170 160

Receiver Monitor

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350 000 010

340 330 320 310 300

020 030 040 050 060

290

070

280

080

270

090

260

100

250

110

240 230 220 210 200 CD-7557

ISSUE 1

120 130 140 150 190 180 170 160

Transmitter Monitor

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.

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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) (2) The Monitor Arm is securely fitted. 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) (2) (3) (4) 9 10 Remove the Transceiver Electronic Module, as detailed in paragraph 20. Remove the Motor from the Transceiver case. Remove brushes from housing and check for wear, replace with new brushes if necessary. Refit brushes, ensuring brush retaining springs are in place, and refit Motor into Transceiver case.

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

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KH1207 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 TRANSCEIVER IS ONLY TO BE CARRIED OUT BY A QUALIFIED TECHNICIAN. NOTE: Repair to the transceiver should only be undertaken by qualified service engineers or Kelvin Hughes and their approved agents. Unauthorised repair of equipment during the Warranty period will invalidate the Warranty. 11 The flow charts in this chapter provide an aid to fault diagnosis on the transceiver/turning 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 by the display. PRE-REQUISITES 12 The diagnostic routines in the flow charts assume that the radar has been working, and that the system is set up for normal operation at the time the fault occurred.

FAILURE MESSAGES 13 The following failure messages may be appear on the data field of the display monitor if certain signals are missing: (1) (2) (3) (4) 14 No Sync - the sync pulses from the transceiver are not being detected at the display. No Video - the radar video from the transceiver is not being detected at the display. No Azimuth - the azimuth pulses from the transceiver are not being detected at the display. No Heading Line - the heading line pulses from the transceiver are not being detected at the display.

Check that the transceiver and associated equipment is switched on and that the antenna is rotating, as follows: (1) (2) Ensure any associated Mains Isolator is switched on. If a TIU is fitted, ensure it is switched on. If it is switched on, check the fuse in the Power Supply is intact, and replace if necessary (fuses can sometimes fail due to age or a transient power surge). If the new fuse fails then there is a fault in the system. If the 40V Power Supply is fitted, ensure it is switched on, and the MAINS ON and MOTOR ON LEDs on the top of the unit are lit.

(3)

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KH1207 Chapter 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) If the antenna is not rotating check that the safety switch on the base of 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.

15

If the above are OK, there is a fault in the system.

PERFORMANCE CHECK DEGRADATION 16 If the performance of your radar has deteriorated, and there are no failure messages, carry out the performance monitor check detailed in paragraph 2 of this chapter and compare the readings with those documented on installation and at the last routine check. 17 If the Tx Monitor Plume is <50% of the original logged value (the reading taken at installation), or the Rx Monitor Sun is <10% of the original logged value (the reading taken at installation) a fault is present in the transceiver. Lower levels of degradation may occur, which can cause performance problems. 18 Note the following: (1) (2) Whether the degradation is in the 'plume' or the 'sun' or both. If there is a significant degradation in the 'plume', the transmitter power 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. If there is significant degradation in the 'sun', there is likely to be a fault in the receiver circuits.

(3)

TEST EQUIPMENT 19 Routine field maintenance requires fault location down to module replacement level. The only test equipment required for fault finding is a high impedance Multimeter.

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KH1207 Chapter 6 PREPARATION FOR FAULT DIAGNOSIS 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. THE EXTERNAL ISOLATION SWITCH, LOCATED ON THE TRANSCEIVER CASING, ONLY REMOVES THE RUN CONTROL AND THE +24V AERIAL MOTOR START SIGNAL. CAUTIONS Handling Of Electrostatic Sensitive Semiconductor Devices. (1) 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 resistor. 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. Use non-magnetic tools when working near the magnetron.

(3)

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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) (2) (3) (4) (5) Remove the four captive screws securing the end cover to the rear of the Transceiver and remove cover. Disconnect Plugs PLF, G, K, M and L from the Transceiver Terminals PCB. Remove the four screws securing the RF Head to the Rotating Joint. Remove the two bolts securing the Transceiver Electronics Module to the sliding rails. 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 Dummy Sync pulse astable output Gated sync pulses Video output Sync Output Rx Sync from Modulator 0V (signal)

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KH1207 Chapter 6

TP1

TP2

TP5 PLA B LK2 A PLC PLD PLE TP3 TP4 PLF PLG PLK TP6 LK1

PLL

PLN

PLM

CD-3839

Figure 1 - Transceiver Terminals PCB : Test Point Location

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KH1207 Chapter 6 (2) Modulator PCB

TP1 - TR1 gate drive pulse TP2 - High Voltage Supply 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 output 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 supply, nominally +14V TP21 - Pulse shaper circuit drive pulses TP22 - MOD_TRIG from micro-controller TP23 - LPRE_PULSE output TP24 - Enable high voltage TP25 - Drive pulse to CTX-A339

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KH1207 Chapter 6

TP15 TP17

PLD TP16

TP11 TP14 TP4

TP25 TP20 TP5 TP6 TP7 TP9 TP12 TP19 TP10 TP2 TP8 TP18

TP13 PLC

TP22 TP1 TP21 PLE TP24

TP3

PLA

PLB

CD-3721

Figure 2 - Modulator PCB : Test Point Location

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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? YES

NO

IS DISPLAY INSTALLATION MENU SET CORRECTLY TO CANBUS OR PARALLEL? YES

NO

SET UP INSTALLATION MENU CORRECTLY

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

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

NO

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

NO

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

TO SHEET 2

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

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KH1207 Chapter 6

FROM SHEET 1

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

NO

SUSPECT DISPLAY / 40V PSU / TIU FAULT AS APPROPRIATE

FAILURE MESSAGE NO SYNC/NO VIDEO ON DISPLAY

FAILURE MESSAGE NO AZIMUTH/ NO HEADING LINE ON DISPLAY

IS THE COAXIAL PLUG CONNECTED ON THE TERMINALS PCB?

NO

RECONNECT CABLE

IS THE ANTENNA ROTATING?

NO

IS THE ANTENNA SAFETY SWITCH SET TO ON?

NO

SET THE ANTENNA SAFETY SWITCH TO ON?

YES

YES

YES

ARE THE RECEIVER/MODULATOR CONNECTIONS PLUGGED IN? YES

NO

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

RECONNECT

ANTENNA TURNING MOTOR/ MOTOR PCB OR STARTER ASSY? YES

NO

CHECK WIRING

VIDEO/NOISE PRESENT AT TP3 ON TERMINALS PCB? YES

NO

TERMINALS PCB FAULT

REPLACE THE MOTOR/ BRUSHLESS MOTOR PCB OR STARTER ASSY

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)

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KH1207 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. 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 resistor. 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. Use non-magnetic tools when working near the magnetron. 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.

(3) 22

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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) (2) 24 Switching the Display or TIU OFF as appropriate. Isolating the Display or TIU, as appropriate.

All setting up procedures are covered under Checks after Unit Replacement. After replacement of any unit full functional checks are to be carried out. To gain access to PCBs and Modules (refer to Figure 4): (1) (2) (3) (4) (5) Remove the four captive screws securing the cover to the rear of the Transceiver and remove cover. Disconnect Plugs PLF, G, K, M and L from the Transceiver Terminals PCB. Remove the four screws securing the RF Head to the Rotating Joint. Remove the two bolts securing the Transceiver Electronics Module to the sliding rails. The Transceiver Electronics Module may now be removed from the Transceiver.

25

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 switches 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
Modulator PCB Assembly Receiver PCB Transceiver Terminals PCB Azimuth PCB Magnetron Assembly Circulator Assembly PIN Diode Driver & Limiter Low Noise Front End Assembly

Identity
CTX-A332 CTX-A356 CTX-A368 CAE-A402/3 CTX-A197 (10kW) 45-646-604 CTX-A512 CTX-A515

Refer to Figure
5 and 8 5 and 8 5 and 8 5 and 8 5 and 8 5 and 8 5 and 8 5 and 8

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KH1207 Chapter 6 27 The following options, refer to Table 2, are also available: TABLE 2 - LOCATION OF OPTIONAL PCBs AND MODULES PCB/Module
Transmitter Monitor PCB Sector Mute PCB (note that Nucleus and Manta displays can drive Sector Mute without CTX-A162 option) Receiver Monitor Cavity Monitor Arm

Identity
CTX-A198 CTX-A162

Refer to Figure
4, 5 and 8 4 and 5

CTX-A173 CAE-A147

4 4

REPLACING MODULES IN THE TRANSCEIVER Removal of Transceiver Terminals PCB (CTX-A368) 28 To remove the Transceiver Terminals PCB proceed as follows: (1) (2) Isolate the Transceiver and gain access to the Transceiver Terminals PCB, as described in Paragraphs 23, 24 and 25(1) and 25(2) only. 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. Disconnect Plugs PLA, C, D, E, and N. Remove the three screws and two pillars securing the Transceiver Terminals PCB and remove the PCB from the Chassis.

(3) (4)

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) (2) (3) Isolate the Transceiver and gain access to the Modulator PCB Assembly, as described in Paragraphs 23, 24 and 25. Remove the Modulator cover by removing the cover retaining nut. Disconnect Plugs PLA, PLB and the Green and Yellow power leads from the Magnetron.

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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: Grid E1 F4 D4 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

LK1 LK2 LK3 LK4 LK5 LK6 LK7

D3 D3 C1

SW1

A7

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 To remove the Receiver PCB proceed as follows: (1) (2) (3) (4) (5) Isolate the Transceiver and gain access to the Receiver PCB, as described in Paragraphs 23, 24 and 25. Disconnect Plugs PLA, C, D and E. Remove the Receiver Assembly (CTX-A364) by removing the five retaining screws. To remove the Receiver PCB from the Receiver Assembly, remove the eight pillars securing the cover and PCB to the baseplate, and separate. Note the positions of Links 1 to 9 if fitted.

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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 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

LK4 LK5

LK6 LK7 LK8 LK9

Removal of Azimuth PCB (CAE-A402/3) 35 To remove the Azimuth PCB proceed as follows: (1) (2) (3) (4) Isolate the Transceiver and gain access to the Azimuth PCB, as described in Paragraphs 23, 24 and 25. Disconnect Plug PLA. Note the position of pointer on scale, then remove the heading line adjustment locking screw. 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) (2) (3) (4) Set link to 90 position (90 azimuth pulses per revolution). 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. Adjust pointer to the position noted before the removal of the PCB. Fit adjustment locking screws. The Heading Line will have to be checked/set up following replacement, refer to Checks After Unit Replacement.

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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) (2) (3) Isolate the Transceiver and gain access to the Magnetron Assembly, as described in Paragraphs 23, 24 and 25. Disconnect the Green and Yellow leads from the Modulator PCB Assembly. 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) Align the RF Head and Rotating Joint, before tightening the Magnetron height adjustment screws as follows: (1) (2) Fit the chassis into the casting and fit the 4 waveguide screws. Ensure that the chassis is correctly seated on the runners and tighten the Magnetron height adjustment screws that are accessible. Remove the chassis, tighten the remaining adjustment screws. Connect the magnetron leads, ensure they do not touch anything. Fit the Modulator cover and then fit the chassis in the casting and reconnect the sockets.

(3) (4) (5) (2)

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.

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KH1207 Chapter 6 Removal of Circulator Assembly (45-646-604) 39 To remove the Circulator Assembly proceed as follows: (1) (2) Isolate the Transceiver and gain access to the Circulator Assembly, as described in Paragraphs 23, 24 and 25. 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) (2) Align the RF Head and Rotating Joint before tightening the Low Noise Front End (LNFE) and Magnetron height adjustment screws. Tighten the Low Noise Front End (LNFE) and Magnetron height adjustment screws as follows: (1) (2) Fit the chassis into the casting and fit the four waveguide screws. Ensure that the chassis is correctly seated on the runners and tighten the Magnetron and LNFE height adjustment screws that are accessible. Remove the chassis, tighten the remaining adjustment screws. Fit the Modulator cover and then fit the chassis in the casting and reconnect the sockets.

(3) (4)

Removal of PIN Diode Driver and Limiter (CTX-A512) 41 To remove the PIN Diode Driver and Limiter proceed as follows: (1) (2) (3) (4) (5) Isolate the Transceiver and gain access to the Diode Limiter, as described in Paragraphs 23, 24 and 25. Disconnect PL1 from PIN Diode Driver PCB. Note the orientation of the PIN Diode Driver and Limiter, by observing the arrow on the front of the unit. 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. 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.

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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) (2) (3) Isolate the Transceiver and gain access to the LNFE, as described in Paragraphs 23, 24 and 25. Disconnect Sockets SKA, SKB and SKC from the LNFE. 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) (2) (3) (4) Fit the chassis into the casting and fit the 4 waveguide screws. Ensure that the chassis is correctly seated on the runners and tighten the LNFE height adjustment screws that are accessible. Remove the chassis, tighten the remaining adjustment screws. Reconnect the sockets. Fit the chassis in the casting.

Removal of Transmitter Monitor PCB (CTX-A198) 45 To remove the Transmitter Monitor PCB proceed as follows: (1) (2) (3) Isolate the Transceiver and gain access to the Transmitter Monitor PCB, as described in Paragraphs 23, 24 and 25. Disconnect Plug PLA. Remove the four fixings securing the Transmitter Monitor PCB and remove the PCB from the Chassis.

Replacement of Transmitter Monitor PCB (CTX-A198) 46 To replace the Transmitter Monitor PCB, reverse the above procedure.

Issue 3

Page 6.23

KH1207 Chapter 6 Removal of Sector Mute PCB (CTX-A162) 47 To remove the Sector Mute PCB proceed as follows: (1) (2) Isolate the Transceiver and gain access to the Sector Mute PCB, as described in Paragraphs 23 and 24. 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) (2) (3) (4) (5) Isolate the Transceiver and gain access to the Rx Monitor Cavity as described in Paragraphs 23, 24 and 25. Disconnect cavity cable from the Terminals PCB PLL. 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. Lower the rotating joint until the four bolts supporting the cavity can be removed. 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 is not available, line up the clamp plate with the inscribed line. Tighten the four screws evenly. Remove the alignment tool and replace the endplate (three screws) noting the position. Replacement is then the reverse of the above procedure. Tune the cavity after replacement, refer to Checks after Unit Replacement.

(2) (3) (4)

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Issue 3

KH1207 Chapter 6 Removal of Monitor Arm (CAE-A147) 51 To remove the Monitor Arm proceed as follows: (1) (2) (3) (4) Isolate the Transceiver and gain access to the Cable Gland, as described in Paragraphs 23, 24 and 25(1). 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. Remove the Monitor Arm fixings and remove the Monitor Arm. 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) (2) 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. 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) (2) (3) (4) Isolate the Transceiver and gain access to the Antenna Motor as described in Paragraphs 23, 24 and 25. Disconnect the motor supplies at the motor terminals. Support the motor whilst undoing the two fixing nuts (through motor plate) located on each side of the motor. Carefully lower the motor and remove from the housing.

Replacement of Motor (Low Speed (CAE-A30-20)) 54 To replace the motor proceed as follows: (1) (2) (3) Replace the motor, carefully meshing the pinion to the gears. Support the motor and fasten the two fixing nuts removed in Paragraph 53 (3). Reconnect the motor supplies.

Issue 3

Page 6.25

KH1207 Chapter 6 Removal of Motor (High Speed (CAE-A30-21)) 55 To remove the Motor proceed as follows: (1) (2) (3) (4) Isolate the Transceiver and gain access to the Antenna Motor as described in Paragraphs 23, 24 and 25. Disconnect the motor supplies at the Brushless Motor PCB, PL2 and PL3. Support the motor whilst undoing the four fixing nuts (through motor plate) located at each corner of the plate. 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) (2) (3) (4) The centre sealing ring should be smeared with grease to allow it to locate smoothly, then fit in place. Ensure that the anti-vibration rings are fitted over the fixing bolt shoulders. Support the motor and fasten the four fixing nuts removed in Paragraph 55 (3). 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) (2) (3) (4) Isolate the transceiver and gain access to the Brushless Motor PCB as described in paragraphs 23, 24 and 25. Disconnect PL1, PL2, PL3 and PL4. Remove the three M4 screws located on the heat sink area and three pillars on the PCB area. 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.

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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) (2) (3) (4) Isolate the transceiver and gain access to the Starter Motor Assembly as described in paragraphs 23, 24 and 25. Disconnect PLA and PLB and the motor leads. Remove the two M4 screws located at the top corners and the two M4 pillars at the lower corners of the mounting plate. Remove the assembly.

Replacement 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) Remove the Antenna, as follows: (1) (2) Release the 4 waveguide nuts and bolts. 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) (3) (4) (5)

Gain access to the Starter Motor Assembly as described in paragraph 25. Undo and retain the 3 screws that secure the top section of the rotating joint to the swing casting. Remove the top section. Undo and retain the 4 nuts and washers holding the rotating joint securing plate onto the threaded pillars inside the gearbox. 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.

Issue 3

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KH1207 Chapter 6 Replacement of Rotating Joint 62 To replace the rotating joint: (1) (2) (3) (4) (5) (6) (7) Ensure that the mating surfaces of the swing casting and the top section of the rotating joint are clean. Apply a thin film of Hycomal Sealant on both surfaces. Secure the top section to the swing casting using the 3 screws retained above. Place the white plastic bush into the drive shaft centre hole. Place the end of the rotating joint into the drive shaft through the bush. Locate the 4 plain washers on top of the securing plate, align with the holes in the corner of the plate. 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). Place 1 plain washer and nut on each threaded pillar and finger tighten to the rotating joint securing plate. Run the top nut down and lock against the securing plate. Replace the antenna as follows: (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. Connect the antenna waveguide to the turning mechanism's rotating joint using the 'O' ring and nuts, washers and bolts. Waterproof the waveguide joint by sealing with a layer of greased plastic compound such as Henleys compound or Denso-Tape. Tighten fasteners holding swing casting to antenna to a torque of 29 Nm.

(8) (9) (10)

(2)

(3)

(4)

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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) Set the TIU power supply switches: SW1 CAE-A30-20 CAE-A30-21 (2) (3) (4) (5) ON (9.9V) ON (9.9V) SW2 ON (26V) OFF (36V) Low speed High speed

To measure the heater current connect an ammeter in series with wire from the TIU Terminals PCB (NNR-A1004) pin 3. Switch the system ON. KEEP AT STANDBY ONLY. DO NOT SWITCH TO RUN. The Heater Current is to be between 0.56A and 0.6A. 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). Switch the system ON. If the current is still low, switch the system OFF and make link LK1 on the Transmitter Modulator PCB (CTX-A332). Switch the system ON. Once the heater current is correct, switch the system OFF.

(6) (7) (8)

Issue 3

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. Check that the array/gearbox alignment mark /\ is correct. Switch ON the Display and operate in a HEAD UP mode and a range of 6 miles. 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. The display 'INSTALLATION MENU' Skew setting is to be adjusted to correct the error.

(2) (3) (4)

(5)

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) (2) (3) (4) (5) Ensure that the Display Tune control is adjusted to obtain the maximum indication (length) of the Tune ribbon at the top of the screen. Switch the Display to OFF. Switch the Transceiver Isolator switch to OFF. Remove the four captive screws securing the cover to the front of the Transceiver and remove cover. Slacken off the Receiver Monitor Cavity Adjuster Locking Screw.

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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) (7) (8) (9) (10) (11) (12) Switch the Display to ON. Switch the Transceiver Isolator switch to ON. Go to RUN and adjust the TUNE control for maximum peak indication on LP. Activate the Performance Monitor. Adjust Receiver Monitor Cavity Adjuster for the maximum diameter sun on the radar screen (3nm range). Tighten the Receiver Monitor Cavity Adjuster Locking Screw and secure the Transceiver cover. The range of the sun is to be measured, refer to Figure 10, using the VRM and recorded in the equipment log book. 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 Check that the Display picture can be correctly tuned on all ranges.

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INTENTIONALLY BLANK

Page 6.32

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KH1207 Chapter 6

WARNING SWITCH OFF AT SAFETY SWITCH

Tx MONITOR ARM (OPTIONAL)

NOTE: WHEN REFITTING UNIT DO NOT DAMAGE MATING FACES OF WAVEGUIDE AZIMUTH PCB CAE-A402-3 AZIMUTH PCB LOCKING SCREW & CALIBRATION GUIDE Rx MONITOR CAVITY CTX-A173 (OPTIONAL)

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

MOTOR STARTER PCB CTX-A359 or MOTOR DRIVE PCB CAE-A236 (AT BACK OF CASTING) SAFETY SWITCH LOCATED ON UNDERSIDE OF CASTING

TERMINALS PCB CTX-A368

DISCONNECT ELECTRICAL PLUGS MODULATOR PCB CTX-A332 & MAGNETRON CTX-A197 (BENEATH COVER) Tx MONITOR PCB CTX-A198 (UNDERNEATH) ANTENNA MOTOR TERMINAL BLOCK TB2 TRANSCEIVER UNIT SHOWN WITH FRONT COVER REMOVED

M5 CHASSIS RETAINING BOLTS

CD-3737

ISSUE 2

Figure 4 - Transceiver Electronics Module: Access

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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 CIRCULATOR ASSEMBLY 45-646-604 RF FILTER

PIN DIODE DRIVER PCB

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

DANGER

Tx MONITOR PCB (OPTION) UNDER CHASSIS

TRANSCEIVER TERMINALS PCB CTX-A368 CHASSIS RETAINING SCREWS

TB2

CD-3835

ISSUE 2

Figure 5 - Transceiver Electronics Module

Page 6.34

HIGH VOLTAGE

13kW

MODULATOR PCB COVER

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

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KH1207 Chapter 6

SHIM

BRUSHLESS DC MOTOR
SHIM

PL3 PL2 PL4

PL1

DRAZAH EVAW OIDAR m2 NAHT SSEL TA

REGNAD

BRUSHLESS MOTOR PCB

CD-3606

ISSUE 2

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

Page 6.36

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KH1207 Chapter 6

CABLE CTX-A513

CABLE CTX-A367

MODULATOR PCB ASSEMBLY CTX-A332

PLB

PLE

PLA

PLD

AZIMUTH PCB CAE-A402-3

CABLE CTX-A410

PLA
PLA

SKA

CABLE CTX-A321

CIRCULATOR 45-646-604

P1 Y

P2 GN

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 KEPT AWAY FROM THE PCB AND MUST NOT TOUCH ANY METAL WORK, INCLUDING THE COVER WHEN FITTED

LOGARITHMIC RECEIVER CTX A364 LOW NOISE FRONT END CTX-A315 EARTH BRAID TO BE SECURED TO MAGNETRON AS SHOWN MAGNETRON CTX-A197
2

CODE No.

PLN

TRANSMITTER MONITOR PCB CTX-A198

CABLE CTX-A168 RF HEAD HEIGHT ADJUSTMENT SCREWS

SMB CONNECTORS LOW NOISE FRONT END DIODE LIMITER FIXING SCREWS

HEADING LINE ADJUSTMENT LOCKING SCREW

PIN DIODE DRIVER & LIMITER CTX-A512

TERMINALS PCB CTX-A368

SER. No.

CABLE CTX-A366

BASE VIEW

SIDE VIEW (RECEIVER COVER REMOVED)

PIN DIODE DRIVER & LIMITER CTX-A512

TOP VIEW

FILTER 45-750-0015-001

PLA

LNFE CTX-A515

WAVEGUIDE SHIM NTX-1194

PIN DIODE DRIVER & LIMITER CTX-A512

PLD

FILTER 45-750-0015-001

TERMINALS PCB CTX-A368

SKA

TUNE

SKB

+5V

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)
CD-6902

Figure 8

Assembly of Transceiver: Component Location

DANGER

PLC

PLE

HIGH VOLTAGE

SKC

I/F

13kW

Issue 3

3 1

FILTER 45-750-0215-001

SIDE VIEW (MODULATOR COVER REMOVED)

Figure 8

Page 6.37/38

KH1207 Chapter 6

TRANSMITTER INTERFACE UNIT NNR-A66

POWER SUPPLY UNIT 45-677-124 TERMINALS PCB NNR-A1004 A +9.9V 0.4V 0V 1R0 LK1 B PLB-3 PLB-4 A +ve WIRE V DROP (0.5mm ) 22.6mV/METRE @ 0.58A -ve WIRE V DROP, VERY LOW DUE TO MULTI-PATH CONNECTIONS
2

Mk 5 TRANSCEIVER CAE-A30-7, -8, -20, -21

TERMINALS PCB CTX-A368 MODULATOR PCB CTX-A332
(NORMALLY OPEN)

LK1 +V PLG-1 0V PLG-2 FILTER INDUCTOR 1R0

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

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KH1207 Chapter 6
340 330 320 310 300 350 000 010 020 030 040 050 060

290

070

280

080

270

090

260

100

250

110

240 230 220 210 200

CD-7555
ISSUE 1

120 130
140

150 190 180 170 160

Receiver Monitor
340 330 320 310 300 350 000 010 020 030 040 050 060

290

070

280

080

270

090

260

100

250

110

240 230 220 210 200 CD-7557

ISSUE 1

120 130 140 150 190 180 170 160

Transmitter Monitor Figure 10 - Performance Monitor Display

Page 6.40

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KH1207 Chapter 7

CHAPTER 7 PARTS LIST

CONTENTS
Paragraph 1 INTRODUCTION Page 7.3

PARTS LISTS
Parts List PL1 PL2 PL3 PL4 PL5 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) Page 7.5 7.5 7.7 7.8 7.11

ILLUSTRATIONS
Figure 1 2 3 Transceiver/Turning Mechanism: Main Assemblies Assembly of Gearbox: Component Location Assembly of Transceiver: Component Location Page 7. 7.6 7.10

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THIS PAGE INTENTIONALLY BLANK

Page 7.2

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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.

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

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KH1207 Chapter 7

RECEIVER MONITOR CAVITY CTX-A173

ASSY OF TRANSCEIVER CTX-A363

DANGER
PLL PLM

ASSY OF CABLEFORM CAE-A283

HIGH VOLTAGE

13kV

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
ASSY. OF GEARBOX ASSY. OF CABLE FORM 2SKM-SWITCH ASSY. OF TRANSCEIVER (10kW) FITTING KIT PERFORMANCE MONITORING KIT (OPTIONAL), comprising: Tx Monitor Arm Rx Monitor Cavity Rx Monitor PCB Cableform 2SKN-7SKA

KELVIN HUGHES PART No.

CAE-A280 CAE-A283 CTX-A363 CTX-A170 CTX-A171 CAE-A147 CTX-A173 CTX-A198 CTX-A168

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

ASSY. OF GEARBOX ASSY. OF CABLE FORM 2SKM-SWITCH ASSY. OF TRANSCEIVER (10kW) FITTING KIT PERFORMANCE MONITORING KIT (OPTIONAL), comprising: Tx Monitor Arm Rx Monitor Cavity Rx Monitor PCB Cableform 2SKN-7SKA

KELVIN HUGHES PART No.

CAE-A245 CAE-A261 CTX-A363 CTX-A170 CTX-A171 CAE-A147 CTX-A173 CTX-A198 CTX-A168

Issue 3

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KH1207 Chapter 7

RX MON CAVITY

Figure 2 - Assembly of Gearbox: Component Location

Page 7.6

Issue 3

CD-3722

KH1207 Chapter 7 PL3 - Assembly of Gearbox: CAE-A280 (Low Speed) ITEM No.
1 2 3 CASTING BEARING 35 x 62 x 14mm WITH SHIELDS TYPE 6007-2Z R.H.P. SHIM BEARING SHIM BEARING SHIM BEARING 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 MAIN GEAR AND SHAFT WING CASTING (CAE-1018 MODIFIED) V SEAL TYPE VA 0095 HEADLAND BEARING 50 x 80 x 16mm WITH SHIELDS TYPE 6010-2Z R.H.P. DRIVE SHAFT GEAR PLATE BEARING 12 x 28 x 8mm WITH SHIELDS TYPE 6001-2Z R.H.P. GEARWHEEL & PINION 2nd STAGE GEARWHEEL & PINION 1st STAGE (106T) PINION MOTOR (20T) SPIROL PIN 2.5 DIA x 16 LG TYPE MDP DISC CARRIER DISC OPTICAL +26V MOTOR START PCB DC MOTOR (LOW SPEED) CASE CASTING 25KW ROTATING JOINT ASSEMBLY OF CABLEFORM RUNNER L.H. RUNNER R.H. ASSY. OF RESTRAINT CORD SPECIAL WASHER CLIP BOLT SPECIAL SPACER NUT SPECIAL NEOPRENE CORD DIA. BAINES SPIROL PIN 2.0 DIA x 12 LG SPIROL TYPE MCS STD. DUTY STST CAD PL. CABLE GLAND BRASS No. 248-S CABLE GLAND BRASS No. 254

DESCRIPTION

KELVIN HUGHES PART No.

CAE-A229 45-173-1548 CAE-4028/1 CAE-4028/2 CAE-4028/3 CAE-4063 CAE-4029 35-781-739 45-173-1545 CAE-4012 CAE- 4004 45-173-1549 CAE-1415 CAE-1605 CAE-1280 20-287-4542-49 CAE-4006 CAE-4005 CTX-A359 CAE-A281 CAE-4002 CAE-A415 CAE-A283 CAE-4014 CAE-4015 CAE-A119 CAE-1110 CAE-4016 CAE-4017 CAE-4030 CAE-1625 5662-202 25-287-001 85-267-872 85-267-874

Issue 3

Page 7.7

KH1207 Chapter 7 PL4 - Assembly of Gearbox: CAE-A245 (High Speed) ITEM No.
1 2 3 CASTING BEARING 35 x 62 x 14mm WITH SHIELDS TYPE 6007-2Z R.H.P. SHIM BEARING SHIM BEARING SHIM BEARING 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 MAIN GEAR AND SHAFT WING CASTING (CAE-1018 MODIFIED) V SEAL TYPE VA 0095 HEADLAND BEARING 50 x 80 x 16mm WITH SHIELDS TYPE 6010-2Z R.H.P. DRIVE SHAFT GEAR PLATE BEARING 12 x 28 x 8mm WITH SHIELDS TYPE 6001-2Z R.H.P. GEARWHEEL & PINION 2nd STAGE GEARWHEEL & PINION 1st STAGE (106T) PINION MOTOR (20T) SPIROL PIN 2.5 DIA x 16 LG TYPE MDP DISC CARRIER DISC OPTICAL BRUSHLESS MOTOR PCB ASSEMBLY OF MOTOR BRUSHLESS (PAPST) CASE CASTING 25KW ROTATING JOINT ASSEMBLY OF CABLEFORM MOTOR MOUNT RUNNER L.H. RUNNER R.H. ASSY. OF RESTRAINT CORD SPECIAL WASHER CLIP BOLT SPECIAL SPACER NUT SPECIAL NEOPRENE CORD DIA. BAINES SPIROL PIN 2.0 DIA x 12 LG SPIROL TYPE MCS STD. DUTY STST CAD PL. CABLE GLAND BRASS No. 248-S CABLE GLAND BRASS No. 254

DESCRIPTION

KELVIN HUGHES PART No.

CAE-A229 45-173-1548 CAE-4028/1 CAE-4028/2 CAE-4028/3 CAE-4063 CAE-4029 35-781-739 45-173-1545 CAE-4012 CAE- 4004 45-173-1549 CAE-1415 CAE-1414 CAE-1280 20-287-4542-49 CAE-4006 CAE-4005 CAE-A236 CAE-A246 CAE-4002 CAE-A415 CAE-A261 CAE-1622 CAE-4014 CAE-4015 CAE-A119 CAE-1110 CAE-4016 CAE-4017 CAE-4030 CAE-1625 5662-202 25-287-001 85-267-872 85-267-874

Page 7.8

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Page 7.9

KH1207 Chapter 7

CABLE CTX-A513

CABLE CTX-A367

MODULATOR PCB ASSEMBLY CTX-A332

PLB

PLE

PLA

PLD

AZIMUTH PCB CAE-A402-3

CABLE CTX-A410

PLA
PLA

SKA

CABLE CTX-A321

CIRCULATOR 45-646-604

P1 Y

P2 GN

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 KEPT AWAY FROM THE PCB AND MUST NOT TOUCH ANY METAL WORK, INCLUDING THE COVER WHEN FITTED

LOGARITHMIC RECEIVER CTX A364 LOW NOISE FRONT END CTX-A315 EARTH BRAID TO BE SECURED TO MAGNETRON AS SHOWN MAGNETRON CTX-A197
2

CODE No.

PLN

TRANSMITTER MONITOR PCB CTX-A198

CABLE CTX-A168 RF HEAD HEIGHT ADJUSTMENT SCREWS

SMB CONNECTORS LOW NOISE FRONT END DIODE LIMITER FIXING SCREWS

HEADING LINE ADJUSTMENT LOCKING SCREW

PIN DIODE DRIVER & LIMITER CTX-A512

TERMINALS PCB CTX-A368

SER. No.

CABLE CTX-A366

BASE VIEW

SIDE VIEW (RECEIVER COVER REMOVED)

PIN DIODE DRIVER & LIMITER CTX-A512

TOP VIEW

FILTER 45-750-0015-001

PLA

LNFE CTX-A515

WAVEGUIDE SHIM NTX-1194

PIN DIODE DRIVER & LIMITER CTX-A512

PLD

FILTER 45-750-0015-001

TERMINALS PCB CTX-A368

SKA

TUNE

SKB

+5V

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)
CD-6902

Figure 3

Assembly of Transceiver: Component Location

DANGER

PLC

PLE

HIGH VOLTAGE

SKC

I/F

13kW

Page 7.10

3 1

FILTER 45-750-0215-001

SIDE VIEW (MODULATOR COVER REMOVED)

Figure 3

Issue 3

KH1207 Chapter 7 PL5 - Assembly of Transceiver: CTX-A363 (10kW) ITEM GRID No. REF. DESCRIPTION
ASSY. OF AZIMUTH PCB ASSY. OF MODULATOR PCB ASSY OF RECEIVER, INCLUDING: ASSY. OF RECEIVER PCB ASSY. OF TERMINALS PCB ASSY. OF SECTOR MUTE PCB (OPTION) DETD ASSY. OF MOUNT PCB LOWPASS FILTER X-BAND ASSY. OF LOW NOISE FRONT END ASSY. OF MAGNETRON (10 kW) X-BAND FILTER CABLEFORM CABLEFORM CABLEFORM CABLEFORM CABLEFORM CABLEFORM WAVEGUIDE SHIM PILLAR RECEIVER COVER MODULATOR PANEL L.H. PANEL R.H. SPACER W/G PLATE LOCKING CIRCULATOR TYPE NJC 3901B PIN DIODE DRIVER AND LIMITER FILTER SHIM TRANSMITTER MONITOR PCB NJRC

KELVIN HUGHES PART No.

CAE-A402/3 CTX-AA332 CTX-A364 CTX-C356 CTX-A368 CTX-A162 CTX-A405 45-750-0015-001 CTX-A515 CTX-A197 45-750-0015-001 CTX-A168 CTX-A365 CTX-A366 CTX-A367 CTX-A410 CTX-A513 NTX-1194 CTX-1025 CTX-4006 CTX-4007 CTX-4008 CTX-4012 CTX-4019 45-646-604 CTX-A512 NTX-1194 CTX-A198

Issue 3

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

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

5 6

ILLUSTRATIONS
Figure 1 2 3 4 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

Issue 3

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 are 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 required (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). 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: Electrical Attenuation: Impedance: 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). 60 MHz 3.4 dB/100m MAX 100 MHz 4.9 dB/100m MAX 75 Ohm CODE number 5344-719 Type ECL 125 (Manufacturers code) 1.25 mm Single Conductor Air spaced Polyethylene Tape Screen 8.3 mm

Issue 3

Page A.3

KH1207 Annex A
220

VIDEO IN

DC SUPPLY

SYNC IN

120

VIDEO OUT

SYNC OUT

60

204

82

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
412 335 25 285 25

DANGER High Voltage

IN LINE POWER SUPPLY UNIT
COMPASS SAFE DISTANCES GRADE I GRADE II DISSIPATION
MANUFACTURED BY

SER.No CODE.No HRC-A28/2 EQUIPMENT CLASS 'B' MASS 10 Kg

HAINAULT ENGLAND

KELVIN HUGHES LTD

1
2

A SMITHS INDUSTRIES PLC COMPANY

MOD RECORD

10

11

XXXX-XX

R1 530
3 1

20 TB3

TB 24V.

TB 0V.

12mm DIA TYPICAL

50

UNIT SUPPLIED WITH FITTING KIT HRC-A494

CD-3834

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

Issue 3

131

570

Page A.5

KH1207 Annex A

Page A.6
SCREEN NOT TERMINATED

TIU NNR-A66-ABAB
PL2

SCR
Bn Bn/W V V/W O B/O

TO PROCESSOR or INTERSWITCH CUSTOM CABLE H

COAXES NOT CONNECTED

14-CORE
PLF
WHITE COAX

1 2 3 4 5 6 7 8
AZ1 nAZ1 AZ2 nAZ2 HL nHL

AZIMUTH CONVERTER CTX-A523

Mk V CAE-A30-20 or CAE-A30-21
4 3

VIDEO

Y G

MAINS PSU 45-690-0041-001

GREY COAX

2 1

SYNC

SCR

PLB 1 PSU ON 2 PSU ON RTN 3 4

PLG

CAN ADAPTER PCB NNR-A981

PLB

W S
SCR
SCREEN NOT TERMINATED

PLA
1 CAN HI 2 CAN LO
B/Bk G/W
R/B

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

W Bk R/G Bn/Bk R/B S T R/Y R/W B/Y B/W G/W

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

HEATERS +ve HEATERS -ve MUTE -15V 0V RUN TX READY TUNE TUNE IND MP LP HEADING LINE

COAX CABLES (J)

LINE RECEIVER RAN-A27-2

VIDEO OUT
VIDEO IN

LONG LENGTH OF LOW LOSS COAX CABLE P

VIDEO OUT

LINE AMPLIFIER RAN-A26

VIDEO IN
COAX CABLES (J)
VIDEO SKE

RUN MUTE MP LP TUNE TUNE IND TX READY AZ N/C RX MON HL N/C N/C GND
PLK

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

TO PROCESSOR or INTERSWITCH
SYNC OUT
SYNC IN

VIDEO SKF SYNC SKH GREY COAX

WHITE COAX

38-CORE

CUSTOM CABLE N

R B O R/Bn P V/Bk R/Bk G/O B/Bk

SYNC OUT

SYNC IN

SYNC SKG

1 2 3 4 5 6 7 9 12 13

+27V 0V +27V +27V 0V 0V +15V AZIMUTH TX MON TX MON RTN

R B

MONITOR ARM

14 RX MON
TB2 1 2 3 4 5 6
SCANNER -VE SCANNER +VE

TB1
+27V 0V
PLB

1 2
SCR
R B G
SCR
MODULATOR +27V MODULATOR 0V

R B
SCR
+15V -15V HEATERS +ve HEATERS -ve

2-CORE SIGNAL CABLE A

R B

TERMINALS PCB NNR-A1004

TB1
NOTE: MOUNT NEAR TIU

+12V/+15V 1 0V 2 -12V/-15V 3
3-CORE SIGNAL CABLE B

R G B

SCR

NOTE: MOUNT NEAR DISPLAY OR INTERSWITCH UNIT

FILTER L N E

50/60Hz, 2-CORE POWER 110V/220V/1 PHASE CABLE I

SCR

R B

1 2 3 4 5 6 7 8 9 10
PLC

R/Bk Bn/Bk W Bk R O R/Bn B P V/Bk

G W/V Bn S/Bn Y/Bn W/Bn S/B S/G Y B/O V G/Y G/B G/Bk
SCR
SCANNER +ve

7 8

SCANNER -ve

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

G W/V Bn S/Bn Y/Bn W/Bn S/B S/G Y B/O V G/Y G/B G/Bk
SCR
NOTE: MOUNT NEAR TRANSCEIVER

Figure 3 - Upmast Transceiver (CAE-A30-20, CAE-A30-21) with Long Cables using CAN Bus Interface: Typical Interconnections
Mk 5 X-Band Upmast Connections Standard & High Speed (Long Cables)
KELVIN HUGHES

Issue 3

EHD-0217

G.S.

22.09.08

KH1207 Annex A SETTING UP PROCEDURE FOR LINE AMPLIFIERS RAN-A26 AND RAN-A27-2 6 The setting up procedure requires the following: (1) (2) 7 A square wave to be transmitted from RAN-A26. 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 ms 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 ms long into the display or a 75 ohm load. 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. Adjust potentiometer RV1 to give an output of 3V peak to peak on the flat part of the pulse. Check the video output pulse low level is between 0.6V and 1.0V above 0V. To compensate cable high frequency loss: (a) (b) Fit resistor R16, 150R 2% Style FX (45-518-161-15). Select a capacitor for C5 position to compensate for leading edge rise time. Use oscilloscope on 250 ns range. If C5 is too large the pulse may have a ripple after the rising edge. Further compensation can be carried out by fitting capacitors to C1, C2, C3, C4 and C8. See Figure 5 for guide to capacitor function.

(2) (3) (4) (5)

(c) (d) (6) (7) (8) (9)

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. Adjust potentiometer RV2 to give an output of 2V peak to peak on the flat part of the pulse. Check that the sync output pulse low level is between 0.6V and 1.0V above 0V. To compensate for cable high frequency loss: (a) (b) Fit resistor R32, 150R 2% Style FX (45-518-161-15). Select a capacitor for C16 position to compensate for leading edge rise time. Use oscilloscope on 250 ns range. If C16 is too large the pulse may have a ripple after the rising edge.

(c)

Issue 3

Page A.7

KH1207 Annex A (d) (10) (11) (12) (13) 8 Further compensation can be carried out by fitting capacitors C12, C13, C14, C15 and C119, See Figure 4 for guide to capacitor function.

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. The video amplitude will be approximately 5V peak to peak. The sync amplitude will be approximately 6V peak to peak 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 less compensation than longer lengths.
C3 + C1 + C8 + C5 C1 +C8 + C5
RV1 SET LEVEL

C2 + C3 + C1 + C8 + C5

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) Cable length (metres) 170m 150R 220pF 220pF 68pF 68pF 30pF -

Video R16 C5 C8 C1 C2 C3 C4

Sync R32 C16 C19 C12 C13 C14 C15

Page A.8

Issue 3

KH1207 Annex B

ANNEX B SECTOR MUTING

CONTENTS

Paragraph 1 2 4 5 8 11 14 INTRODUCTION INSTALLATION SETTING UP PROCEDURES 90 Pulses per revolution from Scanner (Normal Setting) Example 1 180 Pulses per revolution from Scanner (Not Normal Setting) Example 2

Page B.3 B.3 B.3 B.3 B.4 B.4 B.5

TABLES
Table 1 2 3 4 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 Page B.4 B.4 B.5 B.5

Issue 3

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. 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 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:

Issue 3

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 ON ON 2 253 ON ON 3 125 ON ON 4 61 OFF OFF 5 29 OFF OFF 6 13 ON OFF 7 5 OFF ON 8 1 OFF ON

Table 2 - Example 1 - END of SECTOR 260 degrees Set SW2 poles

Pole OFF = (degrees) 259 = or 264 =
1 509 ON ON 2 253 OFF OFF 3 125 ON ON 4 61 ON ON 5 29 ON ON 6 13 ON OFF 7 5 OFF ON 8 1 OFF ON

In this example the required angle cannot be set exactly and the choice of the best compromise must be made. 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.

10

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 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

Page B.4

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 2 127 ON ON 63 OFF OFF 3 31 OFF OFF 4 15 ON ON 5 7 ON OFF 6 3 OFF ON 7 1 OFF ON 8

Pole OFF = (degrees) 98 = or 101 =

255 ON ON

Table 4 - Example 2 - END of SECTOR 260 degrees Set SW2 poles

1 Pole OFF = (degrees) 255 OFF OFF 127 ON ON 2 63 ON ON 3 31 ON ON 4 15 ON ON 5 7 ON OFF 6 3 OFF ON 7 1 OFF ON 8

259 = or 262 =

15 16

The compromise nearest setting to be used must be chosen. 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 2 3 4 Installation Reports and Records Service Reports and Records Copy of Warranty Card Other relevant documentation

Issue 3

Page 1

KH1207 Reports

THIS PAGE INTENTIONALLY BLANK

Page 2

Issue 3