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Disconnect the radar 24VDC power supply in the junction box.
Remove the cables at the radar itself; twist each connector anti-clockwise, in turn.
Remove the bolts holding the radar to the radar bracket.
Carefully lift the radar clear of the bracket.
Protect the ends of the power and data cables to prevent water getting inside them whilst disconnected from the radar.
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The contents are as follows:
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Direct Drive Assembly:
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Additional items you will need:
16mm spanner
Pen
T20 Torx® driver
3mm hex key
5mm hex key
M2.5mm allen key
Pressure Tester
2.1 - Open the Enclosure
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If the radar unit has not already been disconnected, isolate the power supply and then remove the power, data and earth connections.
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| Info |
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Caution: this kit contains high powered magnets in the Rotor Assembly. Please refer to the Health & Safety sheet regarding magnet safety -https://www.magnetexpert.com/health-and-safety-i934 |
Required sub-assemblies and parts
1x SUB0299 Dual 55 Assembly
1x SUB0269 Motor board Assembly
1x SUB0268 Rotor Assembly
1x BOA0099 DD Retro-Fit Board
1x WIR0094 Motor Cable
4x SCR0094VSB M4x10 Skt Csk Screw with threadlock
3x SCR0067VSB M4x12 Skt Cap Screw with threadlock
5x SCR0063VSB M6x12 Skt Cap Screw with threadlock
2x SCR0162VSB M6x16 Skt Cap Screw with threadlock
Test radar base assembly with rotating assy (in-house testing only)
Tools
2.5mm hex key
3mm hex key
5mm hex key
10mm spanner
T20 Torx® key
Torque driver for hex and Torx keys
14mm spanner (for pressure gauge)
16mm spanner
Servisol® grease
Loctite® 243
Soft dry brush
Pressure test kit (Navtech order code: NAV0128)
Hand or foot pump with Schrader fitting
Anti-static surface and wrist strap
Latex (or equivalent) protective gloves
2.1 Open the Enclosure
If the radar unit has not already been disconnected, isolate the power supply and then remove the power, data and earth connections.
Using a 16mm spanner, remove the small breather valve located just to the left of the connectors. A replacement breather valve is supplied in the service kit.
Using a pen, make a small mark across the side of the radome and the chassis to indicate the correct orientation.
Using a T20 Torx® driver, loosen the six bolts that secure the radome to the chassis (replacement bolts and washers are supplied in the service kit).
Once all bolts are equally slack, remove them all fully.
You can now lift off the radome. You may need to gently twist the radome to break the seal with the o-ring.
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2.2
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Remove the Upper Assembly
Turn the rotating dish assembly in order to provide clear access to the small retaining bolts.
Using a 3mm hex key (do not use ball ended drivers), loosen the four small retaining bolts and remove the fifth locking bolt. The bolts are secured with Loctite and will be resistant to movement.
When all bolts have been loosened off and the locking bolt completely released, rotate and carefully lift off the upper assembly from the turntable.
| Note |
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Inspect the metal dish or plastic lens on the rotating assembly for dirt and debris. Clean any debris away using a soft dry brush. |
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2.3
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Remove the drive assembly
| Note |
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Check the 3 pillars have not been loosened |
Carefully unclip and disconnect the multi coloured motor ribbon cable (A) from its edge connector on the main board. Note how the cable is routed so that the new motor cable can be routed in the same fashion on reassembly.
Using a 5mm hex key (do not use a ball-ended driver) , slightly loosen and a 10mm spanner to hold the pillars from loosening, undo and remove the five bolts that secure the motor assembly. These bolts can be discarded.
Once all the bolts are equally slack, remove them completely and keep them safe for refitting later.
Carefully lift the complete drive assembly up slightly from the chassis to provide access to the encoder connection.
Carefully un-clip and disconnect the encoder cable (B) from its edge connector on the main board. Ensure to grip on the latching pin at the top before pulling gently in a vertical motion.
You can now remove the old drive assembly from the chassis and return it to Navtech Radar (using the packaging supplied with the replacement unit).
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2.5a 5a Remove the Maxon Motor Board
Remove the Maxon Motor Board from the main board in the base.
This part is no longer required and should be suitably disposed of.
2.5b Check the Motor Board & Speed Setting
Remove the new Direct Drive Motor Assembly from the packaging and check for damage.
Check speed setting is set to 4Hz:
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Switch 1
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Switch 2
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Switch 3
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Switch 4
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Speed (Hz)
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OFF
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OFF
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ON
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OFF
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4
| Info |
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Other combinations will result in wrong speeds being set. The switch is read once at power up. |
2.5c Strip Down Retro-Fit Assembly to Component Parts
Remove and discard the 3 bolts securing the Rotor Assembly. Please refer to the Health & Safety sheet regarding magnet safety -https://www.magnetexpert.com/health-and-safety-i934
Place the Rotor back into the foam tray supplied with the replacement Direct Drive Assembly.
Take care not to place the Rotor Assembly near any metal which may dislodge the magnets, or metal fragments which may get stuck to the magnets and cause abnormal behaviour.
Contact Navtech if any magnet is dislodged, to ensure correct polarity.
Remove and discard the 4 x M4 screws securing the Motor Board using a M2.5mm allen key.
Set the Motor Board speed then place the Motor Board into the ESD protective bag.
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the base.
Return the old Motor Board to Navtech Radar with the old drive assembly.
2.5c Strip Down Retro-Fit Assembly to Component Parts
Remove and discard the 3 bolts securing the Rotor Assembly.
Place the Rotor back into the foam tray supplied with the replacement Direct Drive Assembly.
Take care not to place the Rotor Assembly near any metal which may dislodge the magnets, or metal fragments which may get stuck to the magnets and cause abnormal behaviour.
Contact Navtech if any magnet is dislodged, to ensure correct polarity.
Remove and discard the 4 x M4 screws securing the Motor Board using a M2.5mm allen key.
Check the Motor Board speed then place the Motor Board into the ESD protective bag.
Remove the new Direct Drive Motor Assembly from the packaging and check for damage.
Check speed setting is set to 4Hz:
Switch 1 | Switch 2 | Switch 3 | Switch 4 | Speed (Hz) |
OFF | OFF | ON | OFF | 4 |
| Info |
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Other combinations will result in wrong speeds being set. The switch is read once at power up. |
| Note |
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Take care when handling the Motor Board to avoid damage. |
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2.5d Daughter Board & Motor Cable Fitting
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Connect the Encoder Cable from the Drive Assembly (SUB0299) to the main board.
If the old drive assembly had 2 spacers underneath the front 2 bolts, then these will need to the main board.Carefully set onto the 3 pillars and secure using be re-fitted with the Drive Assembly using 2 x M6x16mm Skt Cap Screws (SCR0162VSB), then use 3 x M6x12mm Skt Cap Screws (SCR0063VSB) on the 3 pillars.
If there are no spacers under the old drive assembly, then use 5 x M6x12mm Skt Cap Screws (SCR0063VSB) to secure the Drive assembly with a 5mm hex allen key.
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Connect the other end of the Motor Cable to J4 on the Motor Board (SUB0299).
With the radar connections facing towards you, set the Motor Board into position on the 4 pillars of the Drive Assembly with the Motor Cable tucked inside the Casting and with the board speed dip switches set in the 9 o’clock position as shown below.
Secure with 4 x M4x10mm Skt Ctsk Screws (SCR0094VSB). Take care when tightening these 4 screws; they need to be nipped up but not overtightened using a 2.5mm hex bit, Torque=60±5cNm.
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Aligning the 2 dowel pins 9circled (circled in pink below), position 1 x Rotor Assembly (SUB0268) with the magnets facing down onto the Dual 55 Assembly.
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Set 1 x Rotating Assembly onto the dowels and secure with 5 x M4x12mm Skt Cap (SCR0067VSB).
Tighten in sequence as shown below. This is to ensure the rotor sits flat.
Check the rotating assembly spins freely with a visible gap between the motor board coil clamp and the rotor, with nothing touching.
2.8 Replace the Radome
Lower the Radome onto the body of the radar unit, ensuring that the o-ring remains fully within its recess.
As you do so, align the pen marks for radome orientation and also ensure the bolt holes coincide with those in the chassis (rotating the radome once fitted is difficult).
Insert the six new bolts and washers from the service kit and using a T20 Torx® driver, tighten the bolts to a torque of between 140 and 160 cNm.
If cracks are seen running down from the Radome mount holes then before the Radome is fitted, then the area should be cleaned with IPA or an equivalent.
Then the provided Radome stickers can be applied to support the area around the mount holes. This should prevent the cracks extending further while also improving the cosmetic look of the Radome.
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Click the Windows Start button.
Select Control Panel > Network and Internet > Network and Sharing Centre > Change Adapter settings:
Right click Local Area Connection and select Properties.
Highlight Internet Protocol Version (TCP/IPv4), and then click the Properties button.
Set the IP address:
For example, if the radar IP address is 192.168.0.1 then set laptop to 192.168.0.10 or higher. Click Subnet mask to automatically set to 255.255.255.0. Leave Default Gateway blank. Click OK.
Close the window.
3.2
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Setting the Service Date & Checking Vital Signs
The CTS350-X radar sensor has a built in web interface (known as Vertex) which provides default user level access to the radar. This means you can view information but no changes can be made. There is a useful summary of key radar setup and diagnostic information – e.g. IP address, serial number, System Uptime and Radar health (temperature and rotation).
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In order to do this, you first need to login to Vertex.
Access the Vertex interface as discussed earlier in this section.
Click the Login button in the top right hand corner of the screen.
Enter the correct Username and Password. By default these are:
Username: user (all lower case)
Password: Navtech. (including the capital ‘N’ and the full stop)Click Login or press Return. This level of access allows basic configuration changes and log downloads.
Click on the Factory > Radar Hardware button on the left side to display the following page:
In the Service Date option, enter the next date the sensor is due a service and then click the blue Apply button in the lower right corner.
Click the green Commit Changes button to save the settings to the sensor memory.
A message will be displayed when this action has been carried out.
Click the red Action button at the top of the page.
Click the Reboot option to restart the radar sensor.
3.3
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Testing Radar Operation using SPx RadarView
The SPx RadarView application consists of two files which must be located in the same folder (any folder) on your computer: SPXRadarView.exe and SPXRadarView.cpv.
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