Service Manual

ATLAS RADAR 9xxx

Antennas
GR 3004
GR 3013

Item No.: ED 3025 G 142 Edition: 03.98 Order No.: 16-95864

 This document is our property for which we reserve all rights, including
those relating to patents or registered designs. It must not be
reproduced or used otherwise or made available to any third party without
our prior permission in writing.
Alterations due to technical progress are reserved.

STN ATLAS Marine Electronics GmbH

D - 22763 Hamburg

Customer Support Center

Phone: + 49 (0) 180 3 8553

Fax: + 49 (0) 180 3 8554
E-mail: [email protected]

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RADAR 9xxx, Antennas
Service Manual List of Contents

List of Contents

List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Prevention of Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Service Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 X-Band Antenna GR 3004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Drive and Rotation Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.2 The Waveguide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Technical Data of the X-Band Antenna GR 3004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.1 Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.1.1 X-Band (3 cm) 5 Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.1.2 X-Band (3 cm) 8 Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.1.3 Dimensions and weight (Array) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2.3 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Exchanging the Antenna Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.2 Adjusting the Coupling Depth after Replacing the Waveguide . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.3 Tuning the Waveguide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.4 Adjusting the Head Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Exchanging Parts in the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.2 Exchanging the V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.3 Exchanging the Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.4 Exchanging the Pulsor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.5 Exchanging the Set of Gearing GR 3004 G 021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Connections in the Gearbox GR 3004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6.2 Installing and Connecting the Performance Monitor VS 3026 A 007 . . . . . . . . . . . . . . . . . . . . 27

3 S-Band Antenna GR 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.1 Drive and Rotation Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.2 Coaxial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Technical Data of GR 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1 Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1.1 Functional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1.2 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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List of Contents Service Manual

3.3.2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.2.3 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Exchanging Parts of the S-Band Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.1 Exchanging the Antenna Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4.2 Adjusting the Head Flash in the Case of GR 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.3 Mounting the Coaxial Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.4 Exchanging the Drive Motor and the Pulsor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4.5 Exchanging the Antenna Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.5.1 Removing the Antenna Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.5.2 Installing the Antenna Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4.6 Exchanging the Spur Wheel Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4.6.1 Removing the Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4.6.2 Installing the Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.7 Installing and Connecting the Performance Monitor VS 3026 A 008 . . . . . . . . . . . . . . . . . . . . 42

4 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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RADAR 9xxx, Antennas
Service Manual List of Figures

List of Figures

Fig. 2-1 X-Band antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fig. 2-2 Drive transmission ratio of GR 3004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fig. 2-3 Waveguide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fig. 2-4 Slotted array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fig. 2-5 Antenna support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fig. 2-6 Adjusting the coupling depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fig. 2-7 Adjusting the Head Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fig. 2-8 Exchanging the V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fig. 2-9 Exchanging the Pulsor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fig. 2-10 Exchanging the set of gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fig. 2-11 Connections in the Gearbox GR 3004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fig. 2-12 Power supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig. 2-13 Performance Monitor VS 3026 A 007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fig. 3-1 Antenna GR 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fig. 3-2 Drive transmission ratio of GR 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fig. 3-3 Array mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fig. 3-4 Adjusting the Head Flash GR 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig. 3-5 Mounting the coaxial connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fig. 3-6 Bellows and cable gripping sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fig. 3-7 Flanging and mounting the connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fig. 3-8 Exchanging the drive motor and the pulsor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig. 3-9 Exchanging the antenna support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fig. 3-10 Installing the antenna support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fig. 3-11 Exchanging the spur wheel gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fig. 3-12 Installing the gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fig. 3-13 Installing and connecting the Performance Monitor VS 3026 A 008 . . . . . . . . . . . . . . . . . . . . 42

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List of Figures Service Manual

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RADAR 9xxx, Antennas 1 General Information
Service Manual 1.1 Maintenance Work

1 General Information

The descriptions and instructions in this Service Manual are intended as a work aid for the trained service
technician to help him to carry out repairs.
This Service Manual contains the service information for all antenna types that can be supplied. Each
antenna type is described in a self-contained main section, ranging from a description of the structure,
through technical data, service instructions and connection scheme, up to the lists of spare parts.
In the case of antenna types with a directly connected transmitter ("transmitter up"), the interface point is
the transition from the waveguide to the transmitter input.
You will therefore find the technical information about the transmitter in the manual for ATLAS RADAR
TRANSMITTERS.
Please carry out the instructions carefully; in particular, use the stated sequence when assembling.
The following maintenance instructions apply to all antenna types.

1.1 Maintenance Work

WARNING
Before any work is done on the antenna or in its immediate vicinity, the
antenna motor must be switched off at the gearbox (using the switch on
the gearbox casing).

- On the antenna, the V-belt must be examined for wear after every 1000 hours of operation.
- In the case of DC ship’s mains, the condition of the carbon brushes and the commutators of the DC
motors in the converters must be checked for burns and for irregular wear. If any dust from the
brushes is present, it should be removed, because it can cause a short circuit.

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1.2 Prevention of Accidents Service Manual

1.2 Prevention of Accidents

Pay attention to the regulations for the prevention of accidents.

There is a danger of touching electrically live parts.
IMPORTANT
Pay attention to warnings and other notices on and in the units.

When the units are being operated live in the open state during trouble-shooting, obey the regulations for
the prevention of electrical accidents.
DANGER
When the antenna is rotating, there is danger caused by high frequency
radiation.

There are no international standards concerning the danger caused by high frequency radiation of the
kind produced by the radar antenna. In most countries, a radiation density exceeding 100 W/m2 is
regarded as dangerous; in some countries, values over 10 W/m2 are regarded as not being completely
safe.
This distances from the various antennas of the RADAR at which the radiation density is 100 W/m2 and
10 W/m2, respectively, are stated in the following table.

Distance
Antenna type
Radiation density 100 W/m2 Radiation density 10 W/m2
5 ft X-band 1.7 m 17 m
8 ft X-band 1.5 m 15 m
14 ft S-band 0.7 m 7m

DANGER
Never look down into the open waveguide while the transmitter is active!

DANGER
If the antenna is stationary because the system is switched off or
because the radar has been switched into Stand-By Mode, then unless
the antenna switch is set to 0 the antenna can begin to rotate at any
time.

DANGER
Even when the system is switched off, there may still be a dangerous
voltage present on exposed contacts. Therefore, before a unit is opened,
it must be ensured that the electrical supply to the unit is, and remains,
disconnected from the ship’s mains.

Attach a clearly visible warning notice stating that work is being done on the equipment.

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RADAR 9xxx, Antennas 1 General Information
Service Manual 1.3 Service Stations

1.3 Service Stations

If repair work cannot be carried out, an authorised service station should be asked for assistance if
possible.
Repairs under warranty should only be carried out by service stations authorised by STN ATLAS Marine
Electronics GmbH, Hamburg.
Ships operating in areas in which service stations are difficult to reach should carry additional spares
parts on board.

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1.3 Service Stations Service Manual

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RADAR 9xxx, Antennas 2 X-Band Antenna GR 3004
Service Manual 2.1 Structure

2 X-Band Antenna GR 3004

2.1 Structure

The high-resolution X-band antenna (GR 3004) consists of the slotted array, a watertight casing with the
gearing, the drive motor and a pulse generator for synchronisation of the rotation information in the radar
display.
z_ra_001.gif

Fig. 2-1 X-Band antenna

The interior of the gearbox casing is accessible even after the antenna has been mounted on the mast.
In service cases, the hood can be lowered after the four screws have been undone.

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2 X-Band Antenna GR 3004 RADAR 9xxx, Antennas
2.2 Functional Description Service Manual

2.2 Functional Description

2.2.1 Drive and Rotation Signal

The drive motor B1 of the antenna is supplied with power through a three-core cable via the terminals 1,
2 and 3 of the terminal board TB1. For service, the motor can be disconnected from the electrical supply
by means of the switch S1.
The rotation signal is generated by means of a pulsor (an inductive proximity-switch) from a driven
toothed disk which rotates past the pulsor.
During each revolution of the antenna, 576 cycles are generated; these are used in the indicator in order
to display the radar picture in the correct position.
In order to generate the ship’s head flash, a hermetically sealed contact S2 is used; it is operated by a
magnet which rotates with the antenna shaft.

Antenna
RPM1 = 30 min -1
RPM2 = 60 min -1

R1 = 18
Transmission
ratio = 47 : 1
total

R5 ≈ 2.6
V - belt

Pulsor

Motor
B 1 Pulsor disk
z_ra_002.cdr

RPM1 = 1420 min -1

RPM2 = 2850 min -1 576 cycles / revolution
(to CUT assembly)

Fig. 2-2 Drive transmission ratio of GR 3004

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RADAR 9xxx, Antennas 2 X-Band Antenna GR 3004
Service Manual 2.2 Functional Description

2.2.2 The Waveguide

The electrical matching of the scanner to the waveguide system in the antenna gearbox is performed by,
among other things, adjusting the depth of insertion of the coupling pin in the waveguide of the scanner.
The adjustments are carried out in the manufacturer’s factory and must not be changed except by tech-
nicians trained in the manufacturer’s factory.

z_ra_003.gif

Fig. 2-3 Waveguide

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2 X-Band Antenna GR 3004 RADAR 9xxx, Antennas
2.3 Technical Data of the X-Band Antenna GR 3004 Service Manual

2.3 Technical Data of the X-Band Antenna GR 3004

2.3.1 Array

2.3.1.1 X-Band (3 cm) 5 Foot

Antenna type Slotted antenna

Horizontal beamwidth 1.5°
Vertical beamwidth 23.0°
Side-lobe attention within +/-10° >29 dB
Side-lobe attention outside +/-10° >35 dB
Polarisation horizontal
Antenna gain 28 dB
Frequency band 9350 MHz to 9410 MHz
Max. permissible peak transmission power 80 KW

2.3.1.2 X-Band (3 cm) 8 Foot

Antenna type Slotted antenna

Horizontal beamwidth 0.9°
Vertical beamwidth 21.0°
Side-lobe attention within +/-10° >29 dB
Side-lobe attention outside +/-10° >35 dB
Polarisation horizontal
Antenna gain 31 dB
Frequency band 9350 MHz to 9410 MHz
Max. permissible peak transmission power 80 KW

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Service Manual 2.3 Technical Data of the X-Band Antenna GR 3004

2.3.1.3 Dimensions and weight (Array)

X - 5 foot X - 8 foot
Diameter of swing circle [mm] 1700 2600
Height [mm] 160 160
Width [mm] 1678 2578
Depth [mm] 195 195
Weight [kg] 18 22

2.3.2 Gearbox

2.3.2.1 Power Supply

Ship’s mains voltages antenna motor: see Section 4.

Antenna heating (option)

Voltage [Vrms] 380

Phases 3
Frequency [Hz] 50
Power [kVA] 0,2
Heat emmission [kW] 0,2
Fuse (slow-blow) [A] 2

2.3.2.2 Output Signals

Head signal
Contact against ground (protective resistance 680 Ohm)
- Antenna rotation signal
Operating voltage +24 V DC
Max. operating current 20 mA

Output Open collector

Max. load current 200 mA
Max. residual voltage 3V
Cycles (pulses) per
antenna revolution 576
- Performance monitor Auxiliary antenna in gearbox casing

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2.3 Technical Data of the X-Band Antenna GR 3004 Service Manual

2.3.2.3 Dimensions and Weight

Height (mm) 220

Width (mm) 286
Depth (mm) 552
Weight (kg) 38

2.3.3 Environmental Conditions

Permissible mean ambient temperature

During operation (without heating) -25×C to +55×C
During operation (with heating) -40×C to +55×C
During storage -35×C to +70×C
Permissible maximum relative humidity
during operation 98%

Ability to withstand wind Up to 100 knots

Ability to withstand vibration Max. 1 g (5 to 50 Hz)
Type of enclosure IP 54 (watertight)

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Service Manual 2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide

2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide

2.4.1 Exchanging the Antenna Array

When the scanner is being exchanged, care must be taken to ensure adequate electrical matching of the
antenna to the waveguide system in the antenna gearbox.
A slotted array is mounted as shown in the following illustration:
z_ra_004.gif

Fig. 2-4 Slotted array

The slotted array and the antenna support are separate from each other; attention must be paid to the
screws. The antenna is assembled as follows:
- The antenna support (1) is screwed onto the flange of the antenna gearbox.
- The flange surface of the antenna support (2) must be cleaned thoroughly to remove the sealing
compound, and must be degreased (for details, see Figure 2-9 on page 23).

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2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide Service Manual

- Around the six screw-heads (3), apply sealing compound ("ELASTOSIL 33", stock No. 568-0709);
the hexagonal holes of the screw heads must be left free of compound.
- A complete ring (4) of sealing compound about 2 mm thick must be applied as well, situated 5 mm
outside the rubber sealing ring.
- The slotted array must be mounted within 10 minutes after the sealing compound has been applied.
- Put the slotted array onto the antenna support; when doing so, use the set pins to position the slotted
array.
- By means of eight screws, fasten the slotted array from below.
z_ra_005.gif

Fig. 2-5 Antenna support

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Service Manual 2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide

2.4.2 Adjusting the Coupling Depth after Replacing the Waveguide

When a new waveguide is being installed in the gearbox, the height of the coupling pin on the array must
be measured and suitably adjusted.
The height of the coupling pin can be determined by measuring the distance (A) from the choke of the
waveguide in the antenna gearbox to the support surface of the antenna support.
The distance (A) must be 38.5 +/- 0.2 mm. It can be adjusted with the shim washers (0.3 washer: stock
No. 547-5183) in steps of 0.3 mm.
If a change in the coupling depth is necessary, the four hexagon socket-head screws (3) of the
waveguide flange must be undone after unscrewing and opening the sections of the casing. Furthermore,
the two screws (1) of the tuning block must be unscrewed, and the tuning block must be taken off. The
waveguide can then be pulled out of the antenna gearbox, and the shim washers (2) can be inserted to
give the appropriate dimension.
z_ra_006.gif

Fig. 2-6 Adjusting the coupling depth

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2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide Service Manual

2.4.3 Tuning the Waveguide

The adjustment can be optimised by means of the tuning screw (4) on the waveguide (see Figure 2-6 on
page 19). Because, aboard ship, the only indication of satisfactory adjustment is provided by the display
strength of the transmission pulse on the screen in the 0.5 NM range, the following procedure must be
used after the scanner has been mounted:
- Waveguide installation lengths less than 3 m:
The radar can be started up; no fine tuning is needed.
- Waveguide installation lengths greater than 3 m:
If the adjustment is poor after switching the radar on (strong transmission pulse visible on the screen,
possibly with one or two rings), tuning must be carried out.
Screw the tuning screw (4) into the waveguide by a small amount. Undo the two screws (1) and move
the tuning block on the waveguide to obtain minimum transmission pulse; tighten the screws. Turn the
tuning screw (4) until the optimum result is achieved.
VERY IMPORTANT NOTE
Do not turn the screws too far into the waveguide; a small movement
produces a large change.

NOTE
After new installation of a radar with an unfavourable, long waveguide
run, it might be possible to influence the adjustment of the entire
installed waveguide run by turning the adjustment screws (make a note
of the original position!).

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Service Manual 2.4 Exchanging Parts of the Antenna, Adjusting the Waveguide

2.4.4 Adjusting the Head Flash

- Switch off the antenna drive by means of the rotary switch under the gearbox.
- Undo the screws of the casing (3), and lower the hood.
- Undo the two screws (1) and turn the magnet holder (2). Tighten the screws.
- Switch on the antenna drive.
z_ra_007.gif

Fig. 2-7 Adjusting the Head Flash

- Check the position of the head flash on the screen.

- Repeat the adjustment procedure if necessary.
- Fine adjustment (head flash error < 10×) can be performed on the monitor by means of the service
menu (HM adjust), (see Service Manual for RADAR ATLAS 9xxx Electronics Unit).

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2.5 Exchanging Parts in the Gearbox Service Manual

2.5 Exchanging Parts in the Gearbox

2.5.1 General

The exchanging of parts on site is limited to the V-belt for the drive; the drive motor; the pulsor; and reed
relay for the head flash. In order to exchange gearbox parts such as gearwheels and shafts, the antenna
together with the gearbox has to be taken down from the mast.

2.5.2 Exchanging the V-Belt

- Undo the four screws of the hood and lower the hood.
- Release the tensioning screws (1) on the motor base.
- There is already a spare belt in the gearbox, mounted around the waveguide. Put this spare belt into
the pulleys. If this spare belt has been used up, the waveguide together with the rotating coupling
must be removed before a new belt can be installed. To remove the waveguide, unscrew the flange
screws at the bottom and pull the waveguide out downwards.
- By means of the "tensioning screws" (1), adjust the tension of the V-belt in such a way that the motor
shaft is parallel to the antenna shaft.
z_ra_008.gif

Fig. 2-8 Exchanging the V-Belt

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Service Manual 2.5 Exchanging Parts in the Gearbox

2.5.3 Exchanging the Drive Motor

- Switch off the safety switch on the gearbox and the main switch on the ship’s mains distribution
board.
- Undo the four screws of the hood (3) and lower the hood.
- Pull the connecting wires off the plug-in connector.
- Release the tensioning screws (1) on the motor base and take the V-belt off the pulley.
- Unscrew the four screws on the motor flange and exchange the motor.
- Lay the V-belt round the pulleys.
- By means of the tensioning screws (1) on the motor base, tension the V-belt in such a way that the
motor shaft is parallel to the antenna shaft.

2.5.4 Exchanging the Pulsor

- Undo the four screws of the hood (3) and lower the hood.
- Pull the connecting wires off the plug-in connector of the pulsor.
- Unscrew the flange nut (2) and exchange the pulsor.
- The distance between the pulsor’s end face and the pulsor disk should be about 0.6 mm. The
desired duty cycle ratio of 1:1 can be checked in the Transmitter Electronics Cabinet by means of
an oscilloscope at terminal TB 4/5.
z_ra_009.gif

Fig. 2-9 Exchanging the Pulsor

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2.5 Exchanging Parts in the Gearbox Service Manual

2.5.5 Exchanging the Set of Gearing GR 3004 G 021

To exchange the set of gearing, the antenna together with the gearbox must be removed from the mast.
Unscrew the antenna array, see Section 2.4.1. Unscrew the four screws of the hood and remove the
hood. Remove the drive motor, see Section 2.5.3. Remove the waveguide.
Unscrew the flange screws (2) and take off the guide flange of the waveguide’s rotating coupling (inserted
with set-pins).
Remove the lower clamping ring and the magnet disk. Unscrew the cover screws (1) and pull the flange
with the gearwheel upwards out of the lower ball bearing (3). Remove the lower seal and then press the
lower ball bearing out after removing the retaining ring. Take the retaining ring (6) off and pull off the
toothed belt pulley and the V-belt pulley.
Before removing the shaft (4), take off the retaining ring (5) and the spring washer. In the downward
direction, press out the shaft (4) with the two ball bearings. When the set of gear-wheels is being
exchanged, it is a good idea to renew the sealing rings too. To re-assemble, perform the above steps in
the reverse order.
z_ra_010.gif

Fig. 2-10 Exchanging the set of gearing

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Service Manual 2.6 Connections in the Gearbox GR 3004

2.6 z_ra_011.gif Connections in the Gearbox GR 3004

Fig. 2-11 Connections in the Gearbox GR 3004

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2.6 Connections in the Gearbox GR 3004 Service Manual

2.6.1 Power Supply

z_ra_012.gif

Fig. 2-12 Power supply connection

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Service Manual 2.6 Connections in the Gearbox GR 3004

2.6.2 z_ra_013.gif Installing and Connecting the Performance Monitor VS 3026 A 007

Fig. 2-13 Performance Monitor VS 3026 A 007

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2.6 Connections in the Gearbox GR 3004 Service Manual

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RADAR 9xxx, Antennas 3 S-Band Antenna GR 3013
Service Manual 3.1 Structure

3 S-Band Antenna GR 3013

3.1 Structure

The S-Band antenna GR 3013 consists of the slotted array, a watertight casing with the gearing, the drive
motor and a pulse generator for synchronisation of the rotation information in the radar display.
z_ra_014.gif

Fig. 3-1 Antenna GR 3013

The interior of the gearbox casing is accessible even after the antenna has been mounted on the mast.
In service cases, the two hoods can be removed after the cover screws have been released.

3.2 Functional Description

3.2.1 Drive and Rotation Signal

The drive motor B1 of the antenna is supplied with power through a three-core cable which goes from
the terminals 1, 2 and 3 of the terminal board TB1 to the ship’s mains via the three-pole switch S3.
The rotation signal is generated by means of a pulsor (an inductive proximity-switch) from a driven
toothed disk which rotates past the pulsor. During each revolution of the antenna, 576 pulses are gener-
ated; these are used in the indicator for the purpose of synchronisation of the radar picture.
In order to generate the ship’s head flash, a hermetically sealed contact S2 is used; it is operated by a
magnet which rotates with the antenna shaft.

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3.2 Functional Description Service Manual

Antenna
RPM1 = 23.5 min -1
RPM2 = 47 min -1

576 cycles / revolution

(to Indicator)

Pulsor Pulsor disk

R5 ≈ 1.24
T = 12 T = 84
V - belt
Rtotal = 48

Motor Transmission
B 1 ratio = 59.5 : 1
total
T = 96
RPM1 = 1400 min -1
RPM2 = 2800 min -1 T = 14
z_ra_015.cdr

Fig. 3-2 Drive transmission ratio of GR 3013

3.2.2 Coaxial Cable

The antenna signals for transmission and reception are passed via a coaxial cable to the array from the
transmitter and from the array to the receiver. This coaxial cable must be laid carefully, and is provided
with a connector attached in accordance with instructions.

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Service Manual 3.3 Technical Data of GR 3013

3.3 Technical Data of GR 3013

3.3.1 Array

3.3.1.1 Functional Data

S-band (10 cm), 14 foot

Antenna type Slotted antenna
Horizontal beamwidth 1.8×
Vertical beamwidth 20×
Side-lobe attenuation within +/-10× 25 dB
Side-lobe attenuation outside +/-10× 33 dB
Polarisation Horizontal
Antenna gain 28 dB
Frequency band 3020 MHz to 3070 MHz
Max. permissible peak transmission power 80 kW

3.3.1.2 Dimensions and Weight

Diameter of swing circle (mm) 4300

Height (mm) 360
Width (mm) 4220
Depth (mm) 510
Weight (kg) 70

3.3.2 Gearbox

3.3.2.1 Power Supply

Ship's mains voltages antenna motor: see Section 4.

Antenna heating (option)

Voltage [Vrms] 380

Phases 3
Frequency [Hz] 50
Power [kVA] 0,2
Heat emmission [kW] 0,2
Fuse (slow-blow) [A] 2

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3.3 Technical Data of GR 3013 Service Manual

3.3.2.2 Output Signals

Head signal
Contact against ground (protective resistance 680 Ohm)
- Antenna rotation signal
Operating voltage +24 V DC
Max. operating current 20 mA
Output Open collector
Max. load current 200 mA
Max. residual voltage 3V
Cycles (pulses) per antenna revolution 576
- Performance monitor Auxiliary antenna in gearbox casing

3.3.2.3 Dimensions and Weight

Height (mm) 250

Width (mm) 360
Depth (mm) 700
Weight (kg) 105

3.3.3 Environmental Conditions

Permissible mean ambient temperature

During operation (without heating) -25°C to +55°C
During operation (with heating) -40°C to +55°C
During storage -40°C to +70°C
Permissible maximum relative humidity during operation 98%
Ability to withstand wind Up to 100 knots
Ability to withstand vibration Max. 1 g (5 to 50 Hz)
Type of enclosure IP 54 (watertight)

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Service Manual 3.4 Exchanging Parts of the S-Band Antenna

3.4 Exchanging Parts of the S-Band Antenna

3.4.1 Exchanging the Antenna Array

The U-shaped pieces attached to the underside of the array make it easier to centre the array when
placing it on the support.
z_ra_016.gif

Fig. 3-3 Array mounting

- Smear silicone paste onto the centring piece (2) and the sealing ring (4).
- Before setting the array down, align it as accurately as possible relative to the support.
- When installing or removing the array, ensure that the coupling pin (3) does not get damaged.
- Fasten the array by means of the eight hexagon screws (1).
NOTE
Before inserting the screws, smear them with silicone paste to prevent
corrosion.

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3.4 Exchanging Parts of the S-Band Antenna Service Manual

3.4.2 Adjusting the Head Flash in the Case of GR 3013

- Take hold of the antenna array and turn it so that it faces in the ship’s heading direction.
- Release the retaining clamp (1) and turn the magnet (2) until switching of the contact occurs. Secure
the contact again by means of the retaining clamp (1).
- Check the head flash on the indicator; if necessary, re-adjust the position of the magnet (2).
- Fine adjustment (head flash error < 10×) can be performed on the monitor by means of the service
menu (HM adjust), (see Service Manual for RADAR ATLAS 9xxx Electronics Unit).
z_ra_017.gif

Fig. 3-4 Adjusting the Head Flash GR 3013

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Service Manual 3.4 Exchanging Parts of the S-Band Antenna

3.4.3 Mounting the Coaxial Connector

- When the coaxial connector is being mounted, moisture must not be allowed to get into the cable or
connector; this moisture would lead to disturbances on the radar display - bright centre and reduced
range.
- Before mounting, take the plug part (1) of the coaxial connector off after unscrewing the flange
screws (2), and take the rings and washers out of the cable gripping sleeve (3) (Figure 3-5 a)).
- Prepare the cable end according to Figure 3-5 b). Cut off 29 mm of the insulation. Cut off 10 mm of
the outer conductor. Remove the black filling compound from the outer conductor, and clean the
outer conductor with perchloroethylene or trichloroethylene. When stepping the cable down, ensure
that no shavings or other foreign bodies get into the interior of the cable. Do not shift or damage the
insulating helix inside the outer conductor.
z_ra_018.gif

z_ra_019.gif

a) S-Band coaxial connector BN 925 501 b) Cable end

Fig. 3-5 Mounting the coaxial connector

- Push the bellows (2), together with the clamp (1), onto the cable (see Figure 3-6).
- Push the thrust collar (3), the washer (4) and the O-ring (5), one after the other, onto the cable end.
Screw the cable gripping sleeve (6) onto the outer conductor of the cable until it comes to rest
against the plastic sheath (the outer conductor of the cable protrudes by about 2 to 3 mm). Then
screw the thrust collar (3), together with the washer and the O-ring, into the cable gripping sleeve (6).
Tools: Hook-pin spanner 36-60, pin diameter 3.9 mm Face spanner 10-45, pin diameter 2.9 mm

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3.4 Exchanging Parts of the S-Band Antenna Service Manual

z_ra_020.gif

Fig. 3-6 Bellows and cable gripping sleeve

- Using flat-nose pliers, grip the outer conductor (7) which is protuding beyond the edge of the cable
gripping sleeve, and bend it outwards. With the aid of a block of hardwood or fabric-base laminate
and a hammer, flange the outer conductor in the counterclockwise direction (Figure 3-7 a)). The
resulting contact-surface must be flat. If necessary, rework the surface with a file; when doing so,
ensure that the surface is facing downwards so that no filings get into the cavity inside the cable.
- On the inner conductor of the cable, cut a 1/4"-32 UNEF thread with a length of 6 mm (8) (Figure 3-
7 b)). Put on the inner conductor centring cap (9). Screw the inner conductor contact (10) onto the
inner conductor, and tighten it with a hexagon wrench key (4 mm).
- Push the coax connector head (12) onto the cable gripping sleeve, and screw it securely in position
by means of the six screws (11) (Figure 3-7 c)), tightened uniformly.
z_ra_021.gif

z_ra_022.gif

z_ra_023.gif

a) Flanging b) Thread for inner conductor contact c) Assembling

Fig. 3-7 Flanging and mounting the connector

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Service Manual 3.4 Exchanging Parts of the S-Band Antenna

3.4.4 Exchanging the Drive Motor and the Pulsor

Switch off the safety switch on the gearbox and the main switch on the ship’s mains distribution board.

Drive motor B1
- Unscrew the screws of the casing cover (2) and take the cover off.
- Disconnect the wires of the drive motor (3). (Mark the polarity!)
- Undo the fixing screws (5) of the motor support, shift the drive motor, and take the V-belt off the
pulley.
- Unscrew the fixing screws (4) of the drive motor (3).
- Take the motor off the motor support, and replace it with a new motor.
- Mount the new drive motor plus the motor support, put the V-belt (1), and tension the V-belt by
shifting the motor support. Tighten the screws (5).
z_ra_024.gif

Fig. 3-8 Exchanging the drive motor and the pulsor

Pulsor
- For instructions on exchanging the pulsor.
- Disconnect the wires of the pulsor (6) on TB1.
- Unscrew the flange nut (7) and take out the pulsor.
- To install the new pulsor, proceed in the reverse order.
- Put the casing cover on.
- The distance between the pulsor’s end face and the pulsor disk should be about 0.6 mm. The
desired duty cycle ratio of 1:1 can be checked in the Transmitter Electronics Cabinet by means of
an oscilloscope of terminal TB 4/5.

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3.4 Exchanging Parts of the S-Band Antenna Service Manual

3.4.5 Exchanging the Antenna Support

3.4.5.1 Removing the Antenna Support

The antenna support is fixed to the gearbox shaft by means of two clamping elements conical rings (2).
The forces are transmitted by pressure and friction between the working surfaces.
- The cone angle of the individual rings was chosen so that the joint comes apart automatically after
the flange screws (1) have been undone. If necessary, however, gentle tapping will be sufficient to
make the joint come apart. Do not use any tools to force it apart!
- When the clamping rings have come apart, by hand pull the support off the gearbox shaft.
z_ra_025.gif

Fig. 3-9 Exchanging the antenna support

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Service Manual 3.4 Exchanging Parts of the S-Band Antenna

3.4.5.2 Installing the Antenna Support

When mounting the antenna support, particular attention must be paid to controlled tightening of the
clamping screws and to the condition of the contact surfaces.
- All contact surfaces, including the thread and the head contact surface of the clamping screws, must
be clean and must be provided with only a film of oil.
ATTENTION: Do not use molybdenum lubricants!

- The parts are situated in the antenna support in the following sequence: clamping rings I (1) - spacer
(2) - clamping rings II (3) - flange (4). The flange screws (5) are inserted but not securely tightened.
z_ra_026.gif

Fig. 3-10 Installing the antenna support

- Push the support onto the gearbox shaft.

- Tighten the clamping screws (5) slightly and align the hub.
- Tighten the screws uniformly and cross-wise in three stages (10Nm - 20 Nm - 30 Nm) to reach the
specified tightening torque.
- Check the tightening torque of the screws in the order in which they are situated. Mounting is
finished only when each screw is tightened with a torque of at least 30Nm.

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3.4 Exchanging Parts of the S-Band Antenna Service Manual

3.4.6 Exchanging the Spur Wheel Gearing

If the gearing is damaged, the entire gearing must be exchanged in all cases. Furthermore, the
self-aligning ball bearing and the shaft sealing rings should be replaced.

3.4.6.1 Removing the Gearing

- Remove the scanner and the probe transmission.

- Unscrew both casing covers.
- Remove the drive motor, see Section 3.4.4.
- Remove the antenna support, see Section 3.4.5.1
- Unscrew the flange screws (1) of the gearbox shaft.
- With the aid of a pulling device, or by screwing screws into the threaded holes, pull the ball bearing
(2) and the flange off the gearbox shaft.
- Unscrew the four screws (3) of the gearing.
- Press the gearing upwards and take it out of the casing by tilting it.
z_ra_027.gif

Fig. 3-11 Exchanging the spur wheel gearing

For instructions on installing the gearing, see Section 3.4.6.2.

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Service Manual 3.4 Exchanging Parts of the S-Band Antenna

3.4.6.2 Installing the Gearing

- Put the new gearing into the casing.

- Screw the four screws (3) (see Figure 3-10) in and tighten them.
- Exchange the ball bearing (6) in the flange (2). To do this, release the retaining ring (3) after
removing the shaft sealing ring (4), and take the retaining ring out. Press the ball bearing out.
- Press a new ball bearing in and insert the retaining ring.
- Insert the shaft sealing rings (1) and (4).
- Press the flange, together with the ball bearing, onto the gearbox shaft.
- Insert the O-ring (8) and screw the flange screws (7) in.
- Put the antenna support on, and install it, see Section 3.4.5.2.
- Install the drive motor and connect it, see Section 3.4.4.
- Install both casing covers with the sealing strip.
z_ra_028.gif

Fig. 3-12 Installing the gearing

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3.4 Exchanging Parts of the S-Band Antenna Service Manual

3.4.7 Installing and Connecting the Performance Monitor VS 3026 A 008

z_ra_029.gif

Fig. 3-13 Installing and connecting the Performance Monitor VS 3026 A 008

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4 Circuit Diagrams

X-Band Antennas
Drawing No. GR 3004 0 100 SP
Drawing No. GR 3004 A 040 BIS/TO A 045 SP
Drawing No. GR 3004 A 050 BIS/TO A 055 SP
Drawing No. GR 3004 A 060 BIS/TO A 065 SP
Drawing No. GR 3004 A 070 BIS/TO A 075 SP

S-Band Antennas
Drawing No. GR 3013 A 015 BIS/TO A 018 SP
Drawing No. GR 3013 A 025 BIS/TO A 028 SP

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Notes

Space for your notes:

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