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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) 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.
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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5 Remove the Maxon Motor Board
Remove the Maxon Motor Board from the main board in the base.
Return the old Motor Board to Navtech Radar with the old drive assembly.
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6 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:
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Take care when handling the Motor Board to avoid damage. |
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7 Daughter Board & Motor Cable Fitting
Fit Daughter Board (BOA0099) to the Digital Board ensuring fully inserted and correctly positioned with no pins overlapping.
Check this is a tight fit, not loose.
Fit 1 x Motor Cable (WIR0094) to the Daughter Board ensuring it is fully inserted.
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If this is ever disconnected then check the crimps stay fully inserted in the connector. |
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8 Fitting the Drive Assembly
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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 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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9 Fitting the Motor Board
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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Ensure the 4 screws are not overtightened to avoid breaking the clamp ring. Check the Motor Sub Assembly is secure to the 4 pillars with no free movement of the board. |
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10 Rotor Assembly Fitting
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The Rotor is fitted with strong magnets and should not be handled in a dirty environment where it may pick up metallic debris at any time, either loose or in an assembly. Check that the 2 x Flux Rings are aligned concentrically on reverse side. Check each magnet is located correctly in it's pocket in the Rotor and has not been disturbed. Observe caution when handling the magnets. Please refer to the Health & Safety sheet before handling: https://www.magnetexpert.com/health-and-safety-i934 |
Aligning the 2 dowel pins (circled in pink below), position 1 x Rotor Assembly (SUB0268) with the magnets facing down onto the Dual 55 Assembly.
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11 Fit the New Drive Assembly
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.
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14 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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15 Pressure Test the Enclosure
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The power and data connector with its cap on, are hermetically sealed on this radar model and so if fitted will form a gas-tight seal. |
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