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KH 2013 Chap 4 CHAPTER 4 DIAGNOSTICS & MAINTENANCE

CONTENTS

Page

INTRODUCTION DIAGNOSTICS

4.3 4.3 4.3 4.3 4.3 4.4 4.8 4.8

PRE-REQUISITES FAILURE MESSAGES TEST EQUIPMENT TEST POINTS

MAINTENANCE

PREVENTIVE MAINTENANCE

ILLUSTRATIONS

Page

Figure 1 - Antenna terminals PCB: Test Point Locations Figure 2 - Modulator PCB: Test Point Locations Figure 3 - Transceiver Fault Diagnosis (No Sync / No Video) Figure 4 - Antenna Fault Diagnosis (No Azimuth) Figure 5 - Antenna Fault Diagnosis (No Heading Line) Figure 6 - Turning Mechanism (showing brush positions) Figure 7 - Transceiver Electronics Module: Access Figure 8 - Transceiver Electronics Module Figure 9 - Transceiver Electronics Module (Top View) Figure 10 - Transceiver Electronics Module (From Base) Figure 11 - Modulator PCB Assembly and Magnetron Assembly

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TABLES
Page

Table 1 - PCBs and Modules Table 2 - Optional PCBs and Modules

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KH 2013 Chap 4 CHAPTER 4 DIAGNOSTICS & MAINTENANCE

INTRODUCTION
1 This Chapter contains diagnostic and maintenance inf or m a ti o n a p p l i c a b l e to th e Mk V Transmitter/Receiver and Antenna.

FAILURE MESSAGES
4 The failure messages detailed below, appear in the data field of the display monitor if certain signals are missing: Sync/Video Missing

DIAGNOSTICS
2 The Algorithms detailed in Figures 1 to 4 provide an aid to fault diagnosis in the transceiver. Entry to the algorithms is via Failure Messages generated at the display.

Refer to Figures 1 to 4, for fault diagnosis algorithms associated with these failures.

TEST EQUIPMENT
6 Routine field maintenance requires fault location down to fuse replacement level, or to change suspect PCBs/Units for known working ones. The only test equipment required for fault finding is a high impedance Multimeter and a 100MHz oscilloscope.

PRE-REQUISITES
3 Before any fault diagnosis and rectification is implemented, the radar system must be in a standard configuration, as detailed at the top of the appropriate fault diagnosis algorithm.

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TEST POINTS
7 Test Points are located on the following PCBs: (1) Antenna Terminals PCB (2) TP1 - Sync (output to Display). TP2 - Rx Sync (output from Modulator). TP3 - Video (output from Receiver - nominal 6V level). TP4 - +5V. (3) Modulator PCB. (4) TP1 - TR1 Gate Trigger Pulses.

PLA SKT-H RV1 PLB TP4 TP1 PLE PLC PLD TP2 TP3 PLF LK PLG

C4

PLA

TP1

PLB

CD-1532
750 1500

PLK

PLL

PLN

PLM

Figure 2 - Modulator PCB: Test Point Locations

CD-1531

Figure 1 - Antenna terminals PCB: Test Point Locations

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PRE-REQUISITES
1. MAINS ISOLATOR ON 2. DISPLAY POWER ON 3. Tx TIMER ELAPSED 4. INSTALLATION DEFAULTS CORRECTLY SET 5. SET TO RUN

FAILURE MESSAGE "SYNC/VIDEO MISSING" ON DISPLAY

IS THE TRANSCEIVER OPERATIVE?

NO

IS THERE POWER TO THE TRANSCEIVER FROM THE DISPLAY?

NO

SUSPECT DISPLAY FAULT

YES

YES

RECONNECT CABLE

NO

IS THE COAXIAL PLUG CONNECTED ON THE TERMINALS PCB?

IS THE ANTENNA ROTATING?

NO

CHECK THAT SAFETY SWITCH IS ON

YES

YES

IS THERE POWER TO THE NO ANTENNA TERMINALS PCB?

NO

CABLING FAULT

YES

CD-1533

SUSPECT DISPLAY PCBs

TRANSCEIVER FAULT

Figure 3 - Transceiver Fault Diagnosis (No Sync / No Video)

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PRE-REQUISITES
1. MAINS ISOLATOR ON 2. DISPLAY POWER ON 3. Tx TIMER ELAPSED 4. INSTALLATION DEFAULTS CORRECTLY SET 5. SET TO RUN

FAILURE MESSAGE "NO AZIMUTH" ON DISPLAY

NO

IS THE ANTENNA ROTATING?

YES

SET THE ANTENNA SAFETY SWITCH TO ON

NO

IS THE ANTENNA SAFETY SWITCH SET TO ON?

YES

REPLACE THE MOTOR

YES

IS THERE POWER TO THE ANTENNA TURNING MOTOR?

NO

IS POWER PRESENT AT THE TERMINALS PCB?

YES

CHECK WIRING CONNECTIONS NO

SUSPECT THE AZIMUTH/HEADING LINE PCB IN THE TURNING MECHANISM

ARE THE DISPLAY POWER SUPPLY OUTPUTS PRESENT AND CORRECT?

NO

SUSPECT THE POWER SUPPLY UNIT

YES SUSPECT DISPLAY PCB's OR HEADING LINE PCB IN THE TURNING MECHANISM

CD-1534

Figure 4 - Antenna Fault Diagnosis (No Azimuth)

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PRE-REQUISITES
1. MAINS ISOLATOR ON 2. DISPLAY POWER ON 3. Tx TIMER ELAPSED 4. INSTALLATION DEFAULTS CORRECTLY SET 5. SET TO RUN

FAILURE MESSAGE "NO HEADING LINE" ON DISPLAY

NO

IS THE ANTENNA ROTATING

YES

SET THE ANTENNA SAFETY SWITCH TO ON

NO

IS THE ANTENNA SAFETY SWITCH SET TO ON?

YES

REPLACE THE MOTOR

YES

IS THERE POWER TO THE ANTENNA TURNING MOTOR?

NO

IS POWER PRESENT AT THE TERMINALS PCB?

YES

CHECK WIRING CONNECTIONS NO

SUSPECT THE AZIMUTH/HEADING LINE PCB IN THE TURNING MECHANISM

ARE THE DISPLAY POWER SUPPLY OUTPUTS PRESENT AND CORRECT?

NO

SUSPECT THE POWER SUPPLY UNIT

YES SUSPECT DISPLAY PCB's OR HEADING LINE PCB IN THE TURNING MECHANISM

CD-1535

Figure 5 - Antenna Fault Diagnosis (No Heading Line)

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8 The following paragraphs describe preventive maintenance. The Diagnostics information (see paragraphs 10 to 15) complements this.

Antenna Motor/Gearbox
10 The antenna motor brushes should be checked every 6 months or 3000 hours, whichever is sooner. (Refer to Figure 6, below). At the same time, check the commutator for wear. To check, proceed as follows: (1) Remove the Transceiver Electronic Module, refer to Paragraph 24 (Access). (2) Remove the Motor from the Transceiver case. (3) Remove brushes from housing and check for wear, replace with new brushes if necessary. (4) Refit brushes, ensuring brush retaining springs are in place, and refit Motor into Transceiver case. 11 12 The gearbox is lubricated at the factory, and should not normally require attention. Check that the antenna gearbox mounting bolts are secure and kept free of corrosion.

PREVENTIVE MAINTENANCE
Antenna Radiator CAUTION Always switch the radar OFF, and as an additional precaution, switch OFF the antenna safety switch when working on the antenna.

Periodically wipe the antenna front radiating window using soap and water and a soft non abrasive cloth. Even a thin layer of soot or dirt can cause serious loss of radar performance.

CAUTION NEVER PAINT the front radiating window.

TERM L'

L(IN) N(IN)

TERM N' + VE TERM -VE TERM

D RAZAH E VAW OIDA R M2 NAH T SSEL TA

REGN AD

-VE TERM + VE TERM

OFF ON

CD-2189

BRUSHES

Figure 6 - Turning Mechanism (showing brush positions)

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Transceiver
13 The Transceiver requires no periodic maintenance. However, whenever the end cover casting is removed for access to the motor or Transceiver Electronics Module, ensure that the casting seal is clean and clear of obstacles. Check that all unit screws are secure whilst the casting end cover is removed. 14 Whenever the Transceiver Electronic Module is removed, inspect the input cable connections, look for worn seals/grommets, traces of water, loose connections and strands of wire. 15 The Transceiver Unit may be isolated in one of the following ways: (1) Switching the Display OFF. (2) Isolating the Display.

Access
16 To gain access to PCBs and Modules (refer to Figure 7, below): (1) Remove the four captive screws securing the cover to the rear of the Transceiver and remove cover. (2) Disconnect Plugs PLF, G, K, M and L from the Antenna Terminals PCB. (3) Remove the four screws securing the RF Head to the Rotating Joint. (4) Remove the two bolts securing the Transceiver Electronics Module to the sliding rails. (5) The Transceiver Electronics Module may now be removed from the Transceiver. NOTE When refitting any Module/PCB ensure that all Links/Switch positions are identical to those of the removed defective unit.

WARNINGS (1) THIS EQUIPMENT IS NOT FITTED WITH SAFETY INTERLOCKS AND LETHAL VOLTAGES ARE PRESENT WITHIN THE UNIT. BEFORE REMOVING ANY SUB-UNIT OR PCB, ALL SUPPLIES MUST BE SWITCHED OFF. (2) THE EXTERNAL ISOLATION SWITCH, LOCATED ON THE TRANSCEIVER CASING, REMOVES THE +27V MODULATOR SUPPLY INHIBITING THE HIGH VOLTAGE SUPPLY AND THE +24V AERIAL MOTOR SUPPLY.

CD-1474

Figure 7 - Transceiver Electronics Module: Access

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PCBs and Modules in the Transceiver
17 The Transceiver contains the following PCBs and Modules: Table 1 - PCBs and Modules 18 The following options are also available: Table 2 - Optional PCBs and Modules

PCB/Module
Transmitter Monitor PCB

Identity
CTX-A198 CTX-A162

PCB/Module
Modulator PCB Assembly Receiver PCB Antenna Terminals PCB Azimuth PCB Magnetron Assembly Circulator Assembly Diode Limiter Low Noise Front End Assembly

Identity
CTX-A401/4 or A189/2 CTX-A297 CTX-A204 CAE-A402/3 CTX-A414 (5kW) or A197 (10kW) 45-646-604 45-646-603 CTX-A413

Sector Mute PCB (note that Nucleus displays can drive Sector Mute without CTX-A162 option) Receiver Monitor Cavity Monitor Arm

CTX-A173 CAE-A147

DIODE LIMITER AZIMUTH PCB

CIRCULATOR RETAINING SCREWS Rx MONITOR CAVITY

CIRCULATOR ASSEMBLY

SECTOR MUTE PCB (OPTIONAL)

ANTENNA TERMINALS PCB

RECEIVER PCB COVER

MODULATOR PCB ASSEMBLY COVER CHASSIS RETAINING SCREWS

CD-1473

Figure 8 - Transceiver Electronics Module

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AZIMUTH PCB

DIODE LIMITER

CIRCULATOR

CD-1536

HEADING LINE ADJUSTMENT LOCKING SCREW

ANTENNA TERMINALS PCB

Figure 9 - Transceiver Electronics Module (Top View)


ANTENNA TERMINALS PCB

CD-1537

TRANSMITTER MONITOR PCB (OPTION)

Figure 10 - Transceiver Electronics Module (From Base)

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MAGNETRON FIXING SCREWS

MAGNETRON ASSEMBLY

MODULATOR PCB ASSEMBLY

RF HEAD HEIGHT ADJUSTMENT SCREWS

NOTE : MODULATOR PCB ASSEMBLY IS SECURED BY THE FIVE SCREWS AND PILLAR SHOWN
CD-1538

Figure 11 - Modulator PCB Assembly and Magnetron Assembly

LOW NOISE FRONT END AND DIODE LIMITER FIXING SCREWS

LOW NOISE FRONT END FIXING SCREWS RECEIVER PCB LOW NOISE FRONT END

RF HEAD HEIGHT ADJUSTMENT SCREWS


CD-1539

Figure 12 - Receiver PCB and Low Noise Front Assembly

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RAD 1

MP
320

PM
330

350 340

000

010

020

GAIN SEA RAIN

RANGE 12
RINGS 2

030 040

North up
Centred

GYRO 130 deg SPD16.5 kts L(M)


COG SOG STAB SET DRIFT VECTOR TRAILS CPA LIMIT TCPA LIMIT 000 deg 19.0 deg SEA SEA SEA 15 min (R/T) 3 min (R/T) 2.0 min 20.0 min 00.45 N 23.45 E

CORR 1
VIDEO NORM 300 290 310

RM(R)
050

HL OFF
060

070

280

080 LAT LON

050 001

270

090

260

100

250 120 130 220 210 150 200 190 180 170 160 140

110

240

0.8 VRM nm 230 OFF 105.6 EBL deg OFF


G A I N

TARGET 1 BRG 039.3 (T) RANGE 3.3 nm COURSE 349 (T) SPEED 2.7 kts CPA 3.2 nm TCPA 2.2 min

WAY Pt PLOT TRIAL

NAV MAPS VDU

4 5

S E A

R A I N

CD-2543

Figure 13 - Transmitter Monitor and Receiver Monitor

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