KELVIN HUGHES S-Band SharpEye MK7 Navigation Radar Instruction Manual

S-Band SharpEye MK7 Navigation Radar
Instruction Manual

S-Band SharpEye™ MK7 (ASTERIX)
Chapter 3: System overview

System overview

Handbooks

Depending on system configuration. the following handbooks may be associated with an installation: (Note 1)

Information. (Note 2)

Low Profile Antenna (LPA-A3)

Example of an LPA-A3-BAAA (sliver grey)

The DTX-A1-xxxx gearbox is fitted with a 3.9m S-Band Low Profile Antenna that utilises polyrod technology and a horizontally polarised end-fed slotted array enclosed in a polycarbonate plastic case.

PART NUMBERS

FITTING KIT
The antenna is supplied with a fitting kit and a set of lifting slings. Prior to installation, this kit should be identified and the contents checked against the packing note.
The bolts contained in the fitting kit MUST be used to secure the antenna to the gearbox.
Note 1: All handbooks are for ZM-2300 software.
Note 2: HBK-2300-S corrective maintenance is a chargeable handbook provided as part of official HENSOLDT UK training courses.

Transceiver/ turning unit (DTX-A1-XXXX)

DTX-A1-XXXX
Up mast S-band SharpEye™ transceiver/turning unit (ASTERIX).

VARIANTS COVERED BY THIS HANDBOOK
This handbook details the installation of the following variants:

SERVICE ACCESS PANEL
The enclosure is fitted with a maintainer’s removable service access panel that allows access to the interior of the unit. The Service access panel is fitted with a seal to prevent the ingress of moisture and is secured to the enclosure by nine bolts. See section 4.2.6 for details on removing the panel.

STATIC DESICCATOR
An internally mounted static desiccator is located within the housing. This should be changed when the Service Access Panel is opened or removed. See section 9.2 for details.

SIGNAL CONNECTIONS
Control and data to the transceiver is via coper cable and a pre-assembled fibre optic cable.
SFP modules are supplied as part of the fitting kit to allow the fibre optic cable to be connect to the Kelvin Hughes MDC-A201-1 Managed Network Switch which forms part of the HENSODT UK Navigation Display system.

AC POWER

single phase AC supply that should be connected to a suitably rated, dedicated, lockable AC breaker.
Antenna motor| An asynchronous antenna motor fitted to the housing is driven by a 3-phase voltage which is supplied and controlled from an inverter within the GTX-A24 Drive Control Unit.

MAIN COMPONENTS

• Motor/ Gearbox.
• ACP/ ARP Encoder.
• RF Rotary Joint and RF connections to the antenna.
• S-band Fibre SharpEye processor.
• AC/ DC power supply assembly.
• Service AC power switch.
• Static desiccator.

FITTING KIT
The unit is supplied with a fitting kit reference GTX-A250 (see section 4.2.8).

Drive control unit (GTX-A24)

GTX-A24 DRIVE CONTROL UNIT
The GTX-A24 controls the AC power to the antenna motor. The unit is fitted with a static inverter that generates the three phase AC requirements of the antenna motor. The inverter is configured to provide a soft start and a soft stop for the Motor.
CONTROL
A control cable from the DTX-A1-xxxx transceiver connects to the GTX-A24 and controls the RUN/ STOP control of the inverter.

ON / OFF KEYSWITCH
The unit is fitted with an ON/ OFF Keyswitch which is located on the top of the unit. This switches the 3-phase output ON/ OFF but does not isolate the unit from the AC mains supply.

CONNECTIONS AND CABLE
Cabling to and from the drive control unit is via cable glands located at the base of the unit.

AC SUPPLY

220V 50/60Hz AC mains supply.
110VAC| GTX-A234 (OPTIONAL): An optional 110/ 220VAC transformer is available for use where no ships 220VAC supply is available. See Section 10.5 for details.

Typical system

Chapter 4: Mechanical installation

Mechanical installation

The health and Safety notices shown at the beginning of this handbook must be observed at all times when installing, terminating, commissioning, operating and maintaining the equipment and its sub-assemblies.

Pre-installation

Storage conditions

PACKING

Equipment being stored prior to installation or delivery must be kept in its original packing.

• When opened or after any inspection, all equipment must be repacked using the original packing material.
• Shipping clearance and Special Packing Instructions are void if the equipment is unpacked.

ENVIRONMENT:
Equipment must be stored in its original packing in a well-ventilated, dry building or warehouse that provides protection from extremes of temperature, the weather, rodent and insect infestation.

STORAGE TEMPERATURE RANGE
-40°C to +60°C, relative humidity of up to 95% at +40°C

Shelf-life

ELECTRICAL
If no AC mains power is supplied to the equipment for a long period there is a risk that the performance of large capacity electrolytic capacitors can decline.

• When leaving equipment unused for a long time, it is recommended that the system is powered up once every two years and is left switched ON in a standby state for a minimum of 5 hours.
• Where possible and whilst switched ON, the basic functions of the system should be checked to ensure that the system is operational.
• When applying AC power after 2-years of static storage, it is strongly recommended that the AC power is applied gradually using a suitably rated variable AC transformer.

WARRANTY
No provision is allowed to extend the warranty on equipment which will be in storage.

Equipment location/ positioning

For planning and installation purposes, guidance on the location of radar transmission equipment can be found in the following handbook which is available on request. The handbook also contains details on interpreting the radar display.

• HBK-1000: Radar installation guidelines & interpretation of display.

NOTE: The long term storage test procedures for equipment are not defined in this document. Please contact HENSOLDT UK for specific instructions on packing, re-packing, powering and testing of systems.

Equipment inspection

Prior to installation, all equipment should be inspected for any signs of damage that may have occurred during storage or transit.
Equipment should only be installed and operated when all welding, grinding, sanding etc. within the installation area has been completed. All equipment is to be installed in a clean environment that is free from grinding dust, welding spatter, shot blast, moisture, excessive dust etc. Where this is not possible, then the equipment is to be protected to prevent dirt and contamination from work being carried out around the equipment. HENSOLDT UK will not be held liable for damage to equipment as a result of poor environmental conditions encountered pre-commissioning.

Within the warranty period or prior to commissioning, the warranty will be void if the equipment is not correctly installed, operated or stored or where equipment is installed or operated in an unsuitable environment. This includes any damage caused by improper transport and storage.
Any damage must be reported prior to installation. Damaged equipment must only be repaired when authorised by HENSOLDT UK.

Fitting kits

The equipment will be delivered with a range of fining kits. On receipt of equipment, the fining kit(s) should be identified and the contents checked against the packing list provided within the kit.
Particular attention should be made to the turning mechanism fitting kit. The shim washers supplied as part of the installation kit are designed to take up any distortion in the mounting platform.

CAUTION: SHIM WASHERS
Failure to use the shims supplied in the fitting kit on a distorted platform may cause the gearbox casting to crack when bolts are tightened to the correct torque.
Please notify HENSOLDT UK if any of the kit contents are missing.

SFP MODULES
SFP modules are included in the fitting kits and connect the fibre optic cable from the DTX-A1-xxxx to the Kelvin Hughes MDC-A201-1 Managed Network Switch.

Keys

The GTX-A24 Drive Control Unit is delivered with a set of keys for use with the safety switch located on the top of the unit.
When unpacked, the keys can be found attached to the inside of the unit and must be identified and retained with the system.
Please notify HENSOLDT UK if the keys are lost or missing as they are essential for the installation, commissioning and safe operation of the system.

DTX-A1-xxxx

Mounting Plate

Mounting plate:
The mounting structure for the transceiver/gearbox must be capable of withstanding the high starting and stopping torques generated by the Antenna motor and gearbox assembly.
The mast is to be torsionally strong to avoid twisting due to the motor torque. Any deflection in azimuth will compromise bearing accuracy. FOR EXAMPLE, a 0.1° alignment error will result in a target at 11 NM being displaced in azimuth by approximately 35m.

Service platforms:
Safe service access should be provided using service platforms where necessary having a minimum size of 1 m2 at a suitable height and with a safety rail of suitable height.
For turning mechanisms mounted in excess of 1.8m above deck, a working platform should be provided for installing or servicing the assembly. This should be positioned approximately a metre below the base of the turning mechanism housing with a guard rail surrounding it.

Gearbox platform surface:
The gearbox requires a 15mm (minimum) flat steel plate.
The plate should be pre-drilled to accommodate the gearbox, the grounding point and cable access.
Prior to installation, the proposed mounting plate and location must be inspected and accepted as being suitable.
All four planes shown (A, B, C and D) should be checked to ensure the surface is flat and that there is no curvature of the plate. The maximum deviation should not exceed 1.0mm. The shims provided in the fitted kit must be used when mounting the unit.
See section 4.2.7 for dimensions and 4.2.8 for details on the fitting kit.

Weight:
The mounting surface, platform or mast must be able to fully support the weight of the gearbox/ antenna assembly and should be designed to minimise vibration, shock and movement.

Horizontal tolerance:
Once installed the radar antenna should be parallel to the horizon, the horizontal tolerance of a transceiver/ gearbox assembly with respect to the mounting plate/ surface is +/-2.0 degrees.

ILLUSTRATION NOTE
The above is shown for reference and may not represent the actual equipment supplied.

Lifting

The Health & Safety warnings and precautions noted at the beginning of this handbook MUST be observed at all times when lifting ANY equipment.

DO NOT LIFT WITH ANTENNA FITTED.
The gearbox should be securely installed on its mounting position BEFORE the antenna is fitted.
Refer to section 4.3 for details on lifting and installing the antenna.

Tools, torque setting & bolts

TOOLS
In addition to the normal tools required for installation and service work, the following tools will be required:

• 2 x M16 spanners
• Torque wrench (see below for torque values)

MOUNTING BOLTS
The bolts supplied in the fitting kit MUST be used to secure the unit to the mounting platform.

TORQUE VALUES

MAIN MOUNTING BOLTS
The M16 bolts securing the transceiver to the mounting platform| 80Nm
SERVICE ACCESS PANEL
M8 bolts use to restrain the Service Access Panel| 17Nm

NOTE: MOUNTING BOLT LUBRICANT.
As per good engineering practice the mounting bolts should not be dry assembled. A small coating of a suitable lubricant such as Molybdenum Disulphide should be applied prior to assembly.

ADDITIONAL
Any chipped or damaged surfaces must be painted with polyurethane paint.

Grounding

The transceiver/gearbox is supplied with an earthing strap that must be securely connected to a proven and tested earth/ ground point as shown below.
Please refer to the drawing shown in section 4.2.8 (Fitting kit: GTX-A250) for additional details on how the earth strap should be formed and fitted.

GROUNDING TESTS
A secure electrical and mechanical connection must be made. All earth connections must be tested for conductivity using a high current impedance meter such as a Megger or similar.

CORROSION PREVENTATIVE MEASURES
Ensure the earth bonding cannot deteriorate over time. Particular attention should be paid to external earthing points which may corrode. The earth terminals should be protected using local practices; please consult with Hensoldt UK if there is any doubt.

Installation drawings

Please refer to the drawing shown in section 4.2.8 (Fitting kit: GTX-A250) for details on how the unit should be mounted.

Service access panel removal

TOOLS & SPARES
Tools: An M8/ 13mm AF spanner will be required for the removal of the service access panel.
Spares: A replacement desiccator pack is recommended when opening the panel. Please refer to section 9 for details. If the door seal is damaged, it must be replaced; spare part number 55-100-0311-003.

SAFETY CLIPS
There are two safety P-clips located at the top of the housing that must be removed to detach the panel.
The clips are captive and should be reattached after replacing the panel.
SAFETY LANYARD
To prevent a drop hazard, the panel is fitted with an internally mounted safety lanyard. If required this lanyard can be unclipped enabling the panel to be carefully lowered to a safe position.

WEIGHT
The service access panel is heavy, care should be exercised when removing and handling the panel.

ACCESS PANEL BOLTS
There are nine M8/ 13mm AF bolts restraining the panel. Care should be taken when removing these bolts as they are NOT captive.

RELEASE POINTS
The panel is mounted on two locating lugs. It may be necessary to gently leaver the panel open using the two release points marked on the front of the panel.
Care should be taken to ensure the paint is not damaged or chipped during removal and replacement.

REPLACEMENT
Prior to replacing the panel, the following should be checked:

• Ensure that the internally mounted maintenance AC ON/ OFF switch is in the ON position.
• As required, change the desiccator pack as detailed in section 9.
• Ensure the panel is correctly located on the mounting lugs and that the restrain clips have been replaced. Pay attention to the safety lanyard as this can easily become trapped between the panel and the main housing.
• Tighten all bolts on the panel ensuring a full waterproof seal is achieved.
• To prevent corrosion, any chipped or damaged surfaces must be painted with polyurethane paint.

TORQUE VALUE
When replacing the service access panel, the M8 bolts should be tightened to a torque of 17Nm.
MISSING BOLTS?
All bolts must be replaced in the Service Access Panel as missing bolts may lead to water ingress.

HBK-2300-4,Issue 3, April 2021

Documents / Resources

| KELVIN HUGHES S-Band SharpEye MK7 Navigation Radar [pdf] Instruction Manual
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