Introduction
This section describes how to fit the Direct Drive retro-fit method, and includes a list of all components and tools required for this process.
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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.
the radar itself; twist each connector anti-clockwise, in turn.
CAUTION: Ensure you are twisting the connector and not the cable gland on the back of the connector.Remove the bolts holding the radar to the radar bracket.
Carefully lift the radar clear of the bracket.
of the bracket.
IMPORTANT: Take care not to alter the position of the lower mounting nuts. This will ensure that the radar will return to its previously commissioned position when re-mounted.
Failure to do this could mean radar will not perform as expected and may require re-commissioning.Protect the ends of the power and data cables to prevent water getting inside them whilst disconnected from the radar.
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CARE POINT: The radar sensor weighs approximately 6Kg, so please take all necessary precautions when lifting.
2. Replacing the Drive Assembly
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Please contact customer support with your radar model and serial number to obtain the correct kit.
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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
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1 x WIR0094 Motor Cable
4 x SCR0094VSB SCR0094 M4x10 Skt Csk Screw with threadlock
3 x SCR0067VSB SCR0067 M4x12 Skt Cap Screw with threadlock
5 x SCR0063VSB SCR0063 M6x12 Skt Cap Screw with threadlock
2 x SCR0162VSB SCR0162 M6x16 Skt Cap Screw with threadlock
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Servisol® grease
Loctite® 243 - to be used with all screws except the Radome screws
Soft dry brush
Pressure test kit (Navtech order code: NAV0128)
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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.
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CARE POINT: Inspect the metal dish or plastic lens on the rotating assembly for dirt and debris. Clean any debris away using a soft dry brush.
2.3 Remove the Drive Assembly
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.
the motor assembly. These bolts can be discarded.
NOTE: The bolts will be stiff to undo due to being assembled with Loctite 243 at the factory.
CARE POINT: Check the 3 pillars have not been loosened.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.
connector on the main board. Ensure to grip on the latching pin at the top before pulling gently in a vertical motion.
NOTE: Take care when removing this connector. If necessary, disconnect the adjacent Ethernet cable first to provide better access to the retaining clip of the encoder connector.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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CARE POINTS:
Perform a full visual check of the interior of the chassis.
Ensure that no dirt or debris is present within the enclosure
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and pay particular attention to the plastic lens on the fixed optical stack in the radar base.
Clean any debris away using a soft dry brush.
2.5 Remove the Maxon Motor Board
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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. |
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CARE POINT:Take care when handling the Motor Board to avoid damage.
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2.7 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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CARE POINT: If this is ever disconnected then check the crimps stay fully inserted in the connector.
2.8 Fitting the Drive Assembly
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CARE POINTS:
Check the lens at the top of the Beam Splitter is clean.
Ensure the 3 pillars are fully screwed down.
Take care not to trap the Motor Cable when fitting the Dual 55 Assembly or dislodge the Conical Baffle.
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 (SCR0162VSBSCR0162), then use 3 x M6x12mm Skt Cap Screws (SCR0063VSBSCR0063) on the 3 pillars.
If there are no spacers under the old drive assembly, then use 5 x M6x12mm Skt Cap Screws (SCR0063VSBSCR0063) 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).
CARE POINT: If this is ever disconnected then check the crimps stay fully inserted in the connector.
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 (SCR0094VSBSCR0094). 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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CARE POINTS:
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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2.10 Rotor Assembly Fitting
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CARE POINTS:
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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Set 1 x Rotating Assembly onto the dowels and secure with 5 x M4x12mm Skt Cap (SCR0067VSBSCR0067).
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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2.15 Pressure Test the Enclosure
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NOTE: 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.
Insert the pressure test gauge into the hole vacated by the pressure plug and tighten it to form an airtight seal with the enclosure.
Attach a hand or foot pump to the Schrader valve of the pressure test gauge and pressurise the enclosure to approximately 1 psi.
Remove the pump from the pressure test gauge and allow the gauge to settle.
After 5 minutes check the gauge. The pressure should remain at or around 1 psi. If the pressure has dropped by more than 10 to 15%, then the test has failed and your options are to either locate and correct the cause of the leak or return the enclosure to Navtech Radar for a wet pressure test. IMPORTANT: Do not put a radar unit that has failed the dry pressure test back into service, as water ingress could damage the radar.
If this dry pressure test is successful, remove the pressure test gauge and place the new breather valve, supplied in the service kit, into the hole. Use a 16mm spanner to lightly tighten to a torque of between 0.6 and 0.8Nm - do not over tighten.
Apply two new warranty stickers to bridge the join between the Radome and the chassis:
The radar unit is ready for operation and can be returned to its mounting position.
To fully complete the service procedure, you need to register the service date within the radar sensor. Please see the section 3.2 - Setting the service date and checking vital signs for details.
3. Confirming Sensor Operation
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3.1 Preparing & Connecting Your Computer
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IMPORTANT: Ensure that your computer has its IP address set to operate within the same subnet as the Radar Sensor.
The IP address of the radar sensor is preset before leaving Navtech Radar Limited to a default value of 192.168.0.1 unless otherwise specified by the client.
The subnet mask of the radar sensor is often preset to 255.255.255.0 but could also be set wider (such as 255.255.0.0) if requested.
Thus, if the sensor IP address is 192.168.0.1 and the mask is 255.255.255.0, then your computer must use an IP address in the range: 192.168.0.2 to 192.168.0.254.
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NOTE: If you are connecting to the radar via an Ethernet switch rather than making a direct link, it is important that no other radar client software, such as Bloodhound, is already connected before using radar view.
For further details about preparing a computer, please see 3.1.1 - Preparing a computer to link with a radar sensor.
Connecting Your Computer
You can connect your computer at any point along the signal link from the radar sensor, either directly into the sensor mounted socket; at the pole mounted enclosure (if the signal link is joined there) or at the far end of the link where it will join the RPU (Radar Processing Unit) system.
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NOTE: The sensor can be powered on or off while connecting and disconnecting the network link.
The network controller within the radar sensor is autosensing so that you can use either straight through or crossover cables and it will adjust its operation accordingly.
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