Introduction
These are the instructions for 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
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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 243 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.
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.
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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.
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.
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).
CARE POINTS:
Perform a full visual check of the interior of the chassis.
Ensure that no dirt or debris is present within the enclosure 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.
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Remove the new Direct Drive Motor Assembly from the packaging and check for damage.
Remove and discard the 3 bolts securing the Rotor Assembly.
Place the Rotor Assembly 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 is set to 4Hz then place the Motor Board into the ESD protective bag.
Switch 1 | Switch 2 | Switch 3 | Switch 4 | Speed (Hz) |
OFF | OFF | ON | OFF | 4 |
CARE POINT:Take care when handling the Motor Board to avoid damage.
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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.
CARE POINT: If this is ever disconnected then check the crimps stay fully inserted in the connector.
4.2.7 Fitting the Drive Assembly
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.
Remove and discard the tape securing the encoder cable to the underside of the Dual 55 Assembly.
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 (SCR0162) with Loctite 243, then use 3 x M6x12mm Skt Cap Screws (SCR0063) with Loctite 243 on the 3 pillars.
If there are no spacers under the old drive assembly, then use 5 x M6x12mm Skt Cap Screws (SCR0063) with Loctite 243 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 (SUB0269).
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 (SCR0094) with Loctite 243. 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.
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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4.2.9 Rotor Assembly Fitting
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
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4.2.12 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.
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