RADAR 1100 Series: Technical Manual

Technical Manual
RADAR 1100 Series

For New Performance Standards
Including Installation Instructions
Gearboxes GR3017/GR3018/GR3040/GR3041
with Scanner;
Transceiver Electronics Unit
NG3028/NG3029/NG3040/NG3041
(X-Band and S-Band)
Item No.: ED3051G442 Revision: 04 (2008-07) Order No.: 390001632

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.
SAM Electronics GmbH

D - 22763 Hamburg
Service
Customer Support Center
Telephone: + 49 (0) 18 03 00 85 53
Telefax: + 49 (0) 18 03 00 85 54
e-mail:shipservice@sam-electronics.de
t_r1_eti.fm / 23.03.09
Gearboxes and Transceivers
Technical Manual List of Contents
List of Contents
List of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Software Releases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Hardware Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 General Recommendations for Installation, Maintenance and Repair Work . . . . . . . . . . 14
1.4 Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Dangerous High Frequency Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Safety Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6.1 Man Aloft Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6.2 HV Supply Switch (Interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Antenna Unit GR3017 / GR3018 / GR3040 / GR3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.1 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.2 Scanner GR3004 / GR3021 / GR3009 / GR3021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3 Transceiver Electronics Units NG3028 / NG3029 / NG3040 / NG3041 . . . . . . . . . . . . . . . . 22
2.3.1 Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.2 Transceiver Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.3 Components of the Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Compatibility with SAM Electronics Radar / NACOS equipment . . . . . . . . . . . . . . . . . . . . 23
3 Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.1.1 Maximum Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.1.2 Cable Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.1.3 S-Band Coaxial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.1.4 X-Band Flexible Waveguide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.2 Basics about X- and S- Band Waveguides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.3 Electronics Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1.4 Radar Scanner, General Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1.5 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Specific Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.1 Recommendations Concerning the Installation of the Antenna Unit . . . . . . . . . . . . . . . . . . . . . 48
3.2.2 X-Band Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.2.1 Installation of the X-Band Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.2.2 Installation of the X-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2.2.3 S-Band Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2.2.4 S-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.2.3 Gearbox Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ED3051G442 / 04 (2008-07) 3
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List of Contents Technical Manual
4 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 "Power On" Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.3 CAN Bus Concept / Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4.1 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4.2 Description of the Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.2.1 Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.2.2 Motor and Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.4.2.2.1 Toothed Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.4.2.3 Start Unit (S-Band, 3-ph Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.2.4 Antenna Heating (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.2.5 Connection Board (GR3017G200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4.2.5.1 Exchange of Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.4.2.5.2 Motor and Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.4.2.5.3 Shorting Bars for Mains Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.4.2.6 X-Band Azimuth Pulse Generator and Combined Azimuth/Headmarker Pulse Generator . . . 69
4.4.2.7 S-Band Azimuth Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.4.2.8 Headmarker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.4.2.9 Performance Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.5 Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5.1 Modulator NG3028G203 / NG3028G206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.5.1.1 Bias Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5.1.2 Magnetron Selection for NG3028G203/NG3028G206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.5.1.3 Functional Description NG3028G203/NG3028G206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.5.2 Modulator NG3028G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.5.2.1 Magnetron Selection for NG3028G207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.5.3 Pulse Length and PRF (all types of modulators) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.5.4 Microwave Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.5.4.1 X-Band Microwave Unit of NG3028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.5.4.2 X-Band Microwave Unit of NG3040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.5.4.3 S-Band Microwave Unit of NG3029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.5.4.4 S-Band Microwave Unit of NG3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.5.5 IF Amplifier NG3028G022 and NG3028G080 for NG3028/3029 . . . . . . . . . . . . . . . . . . . . . . . 82
4.5.6 HF Unit NG3028G205 for NG3040/3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.5.7 Transmitter Control Unit (TCU) NG3028G201/G221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.5.7.1 Service Switch of the TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.5.7.2 Hardware Description of the TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.5.7.3 Software Description of the TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.5.8 Power Supply Unit NG3028G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.5.9 Mains Input Unit NG3028G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5 Setting-To-Work/Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1 Setting-to-Work Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2 Upgrade Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.1 Gearbox Heating Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.2 X-Band Gearbox Heating Kits GR3017G060 and GR3017G070 . . . . . . . . . . . . . . . . . . . . . . . 96
6 Revision Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.1 Prerequisites for the Use in a RADAR 1100 Series System . . . . . . . . . . . . . . . . . . . . . . . 99
6.1.1 Transceivers NG3028/NG3029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.1.2 Transceivers NG3040/NG3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 ED3051G442 / 04 (2008-07)
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Technical Manual List of Contents
6.2 List of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6.2.1 Hardware for New Performance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7 Repair/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.1 Service Kit NG3028G073 / NG3029G073 for Version A Transceivers . . . . . . . . . . . . . . . 103
7.2 Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.2.1 Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.2.2 System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.2.3 Error 02279 and 04010 appear simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.2.4 Decreasing Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.2.5 Defective Threads for the Gearboxes Cover Locking Screws . . . . . . . . . . . . . . . . . . . . . . . . 106
7.2.6 Humming Noise from the X-Band Gearbox GR3017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.3 Software Update and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.4 Opening the Housings, Removing the Electronics Unit Carrier . . . . . . . . . . . . . . . . . . . . 108
7.4.1 Opening of the Bulkhead Transceiver Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.4.2 Opening of the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.4.3 Swinging out the Electronics Unit Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.4.4 Removing / Installing the Electronics Unit Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.4.5 Replacement of transceivers NG3028/29 by NG3040/41 . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.4.5.1 Gearbox X-Band up, 12,5/25 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.6 Exchange of Parts and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.6.1 Exchange of the S-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.6.1.1 Transceiver Up (GR3009G090 shall be replaced by GR3021G090) . . . . . . . . . . . . . . . . . . . 117
7.6.1.2 Transceiver Down (GR3009G090 shall be replaced by GR3021G090) . . . . . . . . . . . . . . . . . 119
7.6.2 Exchange of the X-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.6.3 Exchange of the X-Band Scanner in Transceiver Down Systems (Bulkhead Version) . . . . . 121
7.6.4 Exchange of Toothed Belts / Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.6.5 Tension of the Toothed Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.6.6 Note about the Exchange of Motors (S-Band) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.6.7 Exchange of Capacitors for 1-ph Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.6.8 Shield Cover with Microwave Absorption Filling (S-Band, former version) . . . . . . . . . . . . . . . 126
7.6.9 Exchange of the Headmarker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.6.9.1 X-Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.6.9.2 S-Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.6.10 Exchange of Azimuth Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.6.10.1 X-Band Azimuth Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.6.10.2 S-Band Azimuth Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.6.11 Exchange of Magnetron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.6.12 Exchange of Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.6.12.1 X-Band Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.6.12.2 S-Band Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
7.6.13 Exchange of TCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.6.14 Exchange of Modulator NG3028G203/206/207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.6.15 Exchange of the IF Amplifier NG3018G022/080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.6.16 Exchange of the HF Unit NG3028G205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.6.17 Exchange of the Power Supply Unit NG3028G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.6.18 Exchange of Connection Board (Transceiver) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.7.1 Magnetron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.7.2 Belt Drive, Toothed Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.7.3 Sealing of the Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.8 Cleaning of the Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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7.9 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

7.9.1 Spare Part Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.9.2 Spare Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

8.1 Conformity to Standards, Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8.2 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8.2.1 Performance Data of the Antenna Unit’s Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
8.2.2 Performance Data of the Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8.2.3 Performance Data of Antenna Heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8.2.4 Performance Data of the Magnetrons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.2.5 Performance Data of the Receiver / HF-Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
8.2.6 Performance Data of the IF Amplifiers NG3028G022/G080 / HF-Unit . . . . . . . . . . . . . . . . . 147
8.2.7 Performance Data of the Modulator NG3028G203 / NG3028G206 / NG3028G207 . . . . . . . 147
8.2.8 Performance Data of the Transmitter Control Unit NG3028G201 / NG3028G221 . . . . . . . . 148
8.2.9 Performance Data of the Power Supply Unit NG3028G202 . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.3 External Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
8.4 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.4.1 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.4.2 Transceiver Electronics Unit (Versions A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.5 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8.6 Compass Safe Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9 System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10 Cabling Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
11 Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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Technical Manual List of Figures
List of Figures
Fig. 1-1 Version label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fig. 1-2 Pcb labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fig. 2-1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fig. 2-2 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig. 2-3 S-Band Gearbox GR3018/GR3041, X-Band Gearbox GR3017/GR3040 . . . . . . . . . . . . . . . . . 20
Fig. 3-1 Preparation of the cable endings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig. 3-2 Cable glands with grounding inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fig. 3-3 Cable inlet consisting of a hole with brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fig. 3-4 Preparation of the connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fig. 3-5 Preparation of the cable end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fig. 3-6 Assembling the connector and sealing with "Plast 2000" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fig. 3-7 Connecting the coax connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig. 3-8 Laying of the X-Band flexible waveguide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fig. 3-9 Positioning of plane fitting and choke fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fig. 3-10 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fig. 3-14 Making a flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fig. 3-16 Assembling (X-Band) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fig. 3-18 Antenna arrangement/positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fig. 3-19 X-Band Antenna Unit, S-Band Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fig. 3-20 X-Band Gearbox flange and Scanner GR3004 (bottom) with holder . . . . . . . . . . . . . . . . . . . . 49
Fig. 3-21 Levelling of uneven mounting plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fig. 3-22 Length of the coupling pin of the X-Band Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fig. 3-23 Assembling the X-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fig. 3-24 S-Band Gearbox with carrier, carrier under Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fig. 3-25 Levelling of uneven mounting plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fig. 3-26 Mounting the S-Band Scanner GR3021G090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fig. 3-27 Mounting the S-Band Scanner GR3009G090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fig. 3-28 Length of the coupling pin of the S-Band Antenna Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fig. 3-29 Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fig. 4-1 Block diagram with wiring concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fig. 4-2 Components of the Gearbox GR3040/3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fig. 4-3 Signal diagram Transceiver NG3040/3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fig. 4-4 S-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fig. 4-5 X-Band Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fig. 4-7 Connection Board Transceiver (example for 3-ph motor), Rev. 01 . . . . . . . . . . . . . . . . . . . . 66
Fig. 4-11 Distance between chopper wheel and pulser end face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fig. 4-12 S-Band pulser with and without shield cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fig. 4-14 Performance Monitor window in X-Band Gearbox, Test Oscillator . . . . . . . . . . . . . . . . . . . . . . 72
Fig. 4-15 Performance monitor, time diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fig. 4-16 Modulator NG3028G206 Rev. 04 (NG3028G203 Rev. 02 with different components) . . . . 73
Fig. 4-17 Modulator NG3028G207 Rev. 00 for advanced performance standards . . . . . . . . . . . . . . . . . 76
Fig. 4-18 X-Band Microwave Unit of NG3028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fig. 4-19 X-Band Microwave Unit of NG3040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fig. 4-20 S-Band Microwave Unitof NG3029 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fig. 4-21 S-Band Microwave Unit of NG3041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fig. 4-24 Transmitter control unit (TCU) NG3028G201, Rev. 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fig. 4-25 Transmitter control unit (TCU) NG3028G221, Rev. 00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Fig. 4-26 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Fig. 5-1 Heating retrofit for the X-Band Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Fig. 7-1 Connection of the service kit NG302XG073STR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fig. 7-2 Transceiver electronics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fig. 7-4 Exchange of the toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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Fig. 7-6 Tension of the belts (example: 2nd stage of X-Band Gearbox) . . . . . . . . . . . . . . . . . . . . . . . 123
Fig. 7-7 Exchange of motor capacitor (X-Band, spare part kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Fig. 10-1 X-Band, Interconnection Transceiver Version A and B, 1/1 . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Fig. 10-2 X-Band, Transceiver Version A, gearbox cabling, 1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Fig. 10-3 X-Band, Transceiver Version A, gearbox cabling, combined HM and Azim. Pulser, 1a/4 . . 157
Fig. 10-4 X-Band, Transceiver Version A, rev. gearbox cabling, comb. HM and Azim. Pulser, 1b/4 . 158
Fig. 10-5 X-Band, Transceiver Version B, gearbox cabling, 2/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Fig. 10-6 X-Band, Transceiver Version B, gearbox cabling, combined HM and Azim. Pulser, 2a/4 . . 160
Fig. 10-7 X-Band, Transceiver Version B, rev. gearbox cabling, comb. HM and Azim. Pulser, 2b/4 . 161
Fig. 10-8 X-Band, Transceiver Version A and B, Motor and Heating cabling, 3/4 . . . . . . . . . . . . . . . . 162
Fig. 10-9 X-Band, Transceiver Version A and B, Motor with Thermoswitch and Heating cabling, 3a/4 163
Fig. 10-10 X-Band, Transceiver Version A and B, 115 V Transformer, 4/4 . . . . . . . . . . . . . . . . . . . . . . 164
Fig. 10-11 X-Band, Transceiver Version B, cabling Interconnection Board, bulkhead housing, 1/1 . . . . 165
Fig. 10-12 S-Band, Interconnection Transceiver, Version A and B, 1/1 . . . . . . . . . . . . . . . . . . . . . . . . . 166
Fig. 10-13 S-Band, Transceiver Version A with Start Unit 2, gearbox cabling, 1/7 . . . . . . . . . . . . . . . . 167
Fig. 10-14 S-Band, Transceiver Version A with Start Unit 2, revised gearbox cabling, 1a/7 . . . . . . . . 168
Fig. 10-15 S-Band, Transceiver Version B with Start Unit 2, gearbox cabling, 2/7 . . . . . . . . . . . . . . . . 169
Fig. 10-16 S-Band, Transceiver Version B with Start Unit 2, gearbox cabling, 2a/7 . . . . . . . . . . . . . . . 170
Fig. 10-17 S-Band, Transceiver Version A and B, Motor and Start Unit 2 cabling, 3/7 . . . . . . . . . . . . . 171
Fig. 10-18 S-Band, Transceiver Version A and B, Motor with Thermoswitch and
Start Unit 2 cabling, 3a/7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Fig. 10-19 S-Band, Transceiver Version A and B, Motor, Heating and Start Unit 1 cabling, 6/7 . . . . . . 173
Fig. 10-20 S-Band, Transceiver Version A and B, 115 V Transformer cabling, 7/7 . . . . . . . . . . . . . . . . 174
Fig. 10-21 S-Band, Transceiver Version B, Connection Board in bulkhead housing, 1/1 . . . . . . . . . . . . 175
Fig. 10-22 X-Band, Transceiver Version B, New Performance Standards, 1/1 . . . . . . . . . . . . . . . . . . . . 176
Fig. 10-23 S-Band, Transceiver Version B, New performance Standards, 1/1 . . . . . . . . . . . . . . . . . . . . 177
Fig. 10-24 X-Band, Transceiver (A), Gear Box Cabling, New performance Standards, 1/4 . . . . . . . . . . 178
Fig. 10-25 X-Band, Transceiver (B), Gear Box Cabling, New performance Standards, 2/4 . . . . . . . . . . 179
Fig. 10-26 X-Band, Transceiver, Motor and Heating Cabling, New performance Standards, 3/4 . . . . . 180
Fig. 10-27 X-Band, Transceiver, Transformer, New performance Standards, 4/4 . . . . . . . . . . . . . . . . . 181
Fig. 11-1 X-Band Antenna Unit, GR3017O000 MB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 11-2 S-Band Antenna Unit, GR3018O000 MB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 11-3 Antenna Unit Mounting Flange S-Band, GR3013T001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fig. 11-4 Antenna Unit Mounting Flange X-Band, GR3004T113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fig. 11-5 X-Band Transmitter, Bulkhead, NG3028O000 MB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Fig. 11-6 S-Band Transmitter, Bulkhead, NG3029O000 MB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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Technical Manual List of Abbreviations
List of Abbreviations
This list also contains abbreviations which are not used in this manual but in additional documentation.
A
A/D Analog/Digital
AFC Automatic Frequency Control
AGP Advanced Graphics Port
ARPA Automatic Radar Plotting Aid
ATA Automatic Tracking Aid
AZS Azimuth Start
B
BSH Bundesamt für Seeschiffahrt und Hydrographie (Federal Maritime and Hydrographic Agency of Germany)
C
CAN Controller Area Network
CD Centred Display
CRR Close Range Resolution
CRT Cathode Ray Tube
CWL Construction Water Line
D
DMA Direct Memory Access
E
EPA Electronic Plotting Aid
ECDIS Electronic Chart Display and Information System
F
FIFO First In First Out (Memory)
FTC Fast Time Constant => Rain (Rain Clutter)
G
GPS Global Positioning System
GVP Graphics and Video Processor
H
HF High Frequency
HM Head Marker
HSC High Speed Craft
HV High Voltage
I
IDE Intelligent Drive Electronics
IEC International Electrotechnical Commission
IF Intermediate Frequency
IMB Interface and Memory Board
ISA Industry Standard Architecture Bus
K
KBC Keyboard Controller
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List of Abbreviations Technical Manual
M
MMI Man-Machine Interface
N
NACOS Navigation and Command System
NI NAVIGATION INTERFACE
NMEA National Marine Electronics Association
NOB Number of Bits
n.c. Not connected/normally closed (break contact)
n.o. Normally opened (make contact)
O
ONP 24 V ON/OFF signal, wire with positive potential
ONN 24 V ON/OFF signal, wire with negative potential (no ground potential)
P
PCB Printed Circuit Board
PCI Processor-Controlled Interswitch, current designation: Interswitch
PCI Peripheral Component Interconnect
PMB Pentium Motherboard
PPI Plan Position Indicator
PRF Pulse Repetition Frequency
PWM Pulse Width Modulation
R
Rev. Revision (as-delivered status), see Section 1.2
RF Radio Frequency
RGB Red Green Blue
RKE Remote Keyboard Electronics
ROT Rate of Turn
RPM Revolutions per Minute
RSC Radar Scan Converter
S
SCSI Small Computer System Interface
SI Ship’s Interface = Interface Expander
SRAM Static Random Access Memory
STC Sensitivity Time Control => Sea (Sea Clutter)
T
TFT Thin Film Transistor
T/R Transmitter/Receiver
TCU Transmitter Control Unit
TM True Motion
TVA Trigger Video Azimuth (Combined Video)
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Gearboxes and Transceivers 1 General
Technical Manual 1.1 Software Releases
1 General
This Technical Manual is the technical reference manual for:

- X-Band Gearbox GR3017 with Scanners GR3004G150 (5 ft), GR3004G160 (8 ft),
GR3020G150 (5 ft) and GR3020G160 (8 ft)
- S-Band Gearbox GR3018 with Scanner GR3009G090 (14 ft) and GR3021G090 (14 ft)
- X-Band Transceiver NG3028, Version A (antenna/mast head) and Version B (bulkhead)
- S-Band Transceiver NG3029, Version A (antenna/mast head) and Version B (bulkhead)
and for systems which cover the advanced performance standards:
- X-Band Gearbox GR3040 with Scanners GR3020G150 (5 ft) and GR3020G160 (8 ft)
- S-Band Gearbox GR3041 with Scanner GR3021G090 (14 ft)
- X-Band Transceiver NG3040 Version A (antenna/mast head) and Version B (bulkhead)
- S-Band Transceiver NG3041, Version A (antenna/mast head) and Version B (bulkhead)
NOTE:
Most of the parameterization and adjustments of the transceiver must be performed at the Display Elec-
tronics Unit. Because of this reason, everything which is displayed at the Indicator (e.g. fault codes) or
operated/performed by means of the Indicator is described in the technical manual of the Display Elec-
tronics Unit.
NOTE:
See Section 6 on page 99 for necessary hard-/software versions for the use in a 1100 series system.
1.1 Software Releases
The pcbs of the Transceiver are programmed with software ex works. Depending on the revision of the
pcbs, a software update can be performed via the Indicator or it must be performed by means of an
exchange of EPROMs.
The software versions must be suitable to the software version of the Display Electronics Unit. See the
software release notes and technotes for information on the software versions.
In order to meet the advanced performance standards, a RADAR/MULTIPILOT software of the Display
Electronics Unit with a version 5.0.0 or higher needed.
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1 General Gearboxes and Transceivers
1.2 Hardware Versions Technical Manual
1.2 Hardware Versions
IMPORTANT!
The Transceivers NG3028 and NG3029 are used for the RADAR 1000
series and for the RADAR 1100 series. For the use with the RADAR 1100
series, only newer revisions of some components must be used. For an
overview, see Section 6 on page 99. When older revisions are used, the
correct function is not ensured.
Hardware for advanced performance standards:
From software version 5.0.0. on, the MULTIPILOT/RADARPILOT fulfils

the advanced performance standards of IEC 62388.
Prerequisites are, that the transceiver and its related hardware are
manufactured or upgraded to the correct hardware standard and that
the appropriate software is installed. Please refer to chapter 2.5 and to
the manuals stated below for details.
Related Documentation:
Unit/Parts System Documentation

Transceivers/Gearboxes RADAR 1000 Technical manual ED3038G442
Transceivers/Gearboxes RADAR 1100 Technical manual ED3051G442
RADAR 1100/CHARTRADAR 1100 RADAR 1100 Operation Instructions ED3051G252
without TRACKPILOT
RADAR 1100/CHARTRADAR 1100/
CONNINGPILOT 1100 with TRACK- RADAR 1100 Operation Instructions ED3051G532
PILOT
MULTIPILOT 1100/CONNINGPILOT RADAR 1100 Operation Instructions ED3051G522
1100 with TRACKPILOT
12 ED3051G442 / 04 (2008-07)
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Technical Manual 1.2 Hardware Versions
All pcbs and units are labelled with a sticker which shows the revision (Rev.) and the print version (for
pcbs only). Modifications on a pcb or a unit (form, fit or function affected) cause a new revision which is
marked by a figure (-, 01, 02, 03...). The numbering of the Rev. is continuous, even when a new print is
used for a pcb. If no revision is marked, the first revision number on the label is valid.
The print version of a pcb is marked by means of characters. The original version is marked with "-"; the
following versions are marked with A, B, C, ... . Sometimes it is possible to update pcbs with an older
print version to a higher revision, and so the print version is not a reliable characteristic for the revision
of a pcb.
Rev., marked by "X"

ztr1_139.jpg
Order No. Item No. of Serial No.

the complete
pcb with all
components
Fig. 1-1 Version label
The pcbs are marked with their print version. The revision status is not recognizable.
ztr1_179.jpg
Item No. of the pcb itself, Print version

without any components
Fig. 1-2 Pcb labelling
If an item has to be exchanged, the same revision or a newer one must be used.
Refer to Section 6, R e v i s i o n O v e r v i e w for further information.
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1.3 General Recommendations for Installation, Maintenance and Repair Work Technical Manual
1.3 General Recommendations for Installation, Maintenance and Repair Work
SAM Electronics gives advice and recommendations for the arrangement of SAM Electronics equipment
and the installation sites. A prerequisite is that the necessary drawings of the ship should be made avail-
able in good time.
This advice and these recommendations are given on the basis of our up-to-date practical experience
and to the best of our knowledge. However, they are given without any commitment. As far as is permis-
sible, any liability on the part of SAM Electronics for resulting damage is expressly ruled out, regardless
of whether the damage is of a direct or indirect nature.
Unusual shipbuilding shapes, additions or superstructures as well as environmental influences can impair
the functioning of the equipment. We are, of course, willing to help the customer with optimizing solutions
subject to suitable commercial arrangements.
The customer is responsible for ensuring that SAM Electronics equipment is installed properly according
to our instructions and in compliance with the regulations issued by the relevant classification society and
national authorities.
1.4 Safety Warnings
WARNING
This unit contains electrostatic sensitive devices.
Observe precautions for handling.
The discharge of electrostatic energy into a semiconductor can destroy the semiconductor or change its
properties. Before a unit’s housing is opened to remove or touch a board, the service equipment, Order
No. 586-5011, must be used.
1. The mat must be positioned at the workplace.
2. The potential equalization cable must be connected to the snap fastener and the clamp to a suitable
protective earth contact. The cable contains a 1 M resistor which must not be removed.
3. The wrist band must be put on. When the spiral cable is connected to the snap fastener, the
discharge line is established.
4. Thoroughly grounded soldering, measurement and test tools must be used. If these tools are
supplied with power from the 230 VAC mains, this supply must be protected by a fault current plug,
stock No. 593-8099.
Boards and units that contain ESD-endangered semiconductors are marked with the symbol shown
above.
All assisting persons who might come into contact with the endangered boards must also use the ESD
equipment.
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Technical Manual 1.4 Safety Warnings
DANGER
It is not permissible to connect the ship’s mains to the
system before setting-to-work by a qualified technician.
The mains must be switched off (e.g. by means of a
common isolating switch or a circuit breaker) in the ship’s
supply or the mains cable must be disconnected until
setting-to-work takes place.
If a synchro or a stepper is connected to the Analog Inter-

face or Interface Expander, dangerous voltages might be
present, even although all supplies to the radar system are
switched off.
Capacitors and tubes can store dangerous voltages for

several hours, even when they have been disconnected
from the supply voltage.
The man aloft switch in the Gearbox switches only the

mains supply for the motor, and so dangerous voltages are
present, even when the switch is set to position 0.
WARNING
Pay attention to the regulations for the prevention of accidents.
DANGER
Even when the system is switched off, there might be a
dangerous voltage present on exposed contacts. Therefore,
before a unit is opened, it must be ensured that the elec-
trical supply to all units is, and remains, disconnected from
the ship’s mains.
DANGER
If the scanner is stationary because the system is switched
off or because the radar has been switched into stand-by
mode, then unless the man aloft switch is set to 0 the
scanner might begin to rotate at any time.
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1.5 Dangerous High Frequency Radiation Technical Manual
1.5 Dangerous High Frequency Radiation
DANGER
When the Scanner is rotating, there is a danger caused by
high frequency radiation. Do not connect the system to the
ship’s mains before setting-to-work by a qualified techni-
cian.
During normal operation, the transmitter is automatically

switched off with a delay of 30 s, if the speed of the
Scanner continuously falls short of 50% of its nominal
speed. This function is disabled, if the service mode is acti-
vated (switch S1/8 on the IMB or S1/8 on the TCU)!
DANGER
Never look down into the open waveguide while the trans-
mitter is active. Therefore, before any work in the cabling
is done, it must be ensured that the electrical supply to the
unit is, and remains, disconnected from the ship’s mains.
☞ There is no international agreement about the danger posed by high frequency radiation of the kind
produced by the radar systems. In most countries, a radiation density exceeding 100 W/m2 is considered
to be dangerous; in some countries, values over 10 W/m2 are regarded as not being completely safe.
Radius of the Radiation Danger Zone

Transceiver
Antenna Type Radiation Density Radiation Density Radiation Density
A=Up B=Down
100 W/m2 50 W/m2 10 W/m2
5 ft X-Band 12.5 kW, Version A 1.4 m 2,8 m 14 m
25 kW, Version A 2.1 m 4,2 m 21 m
25 kW, Version B 1.65 m 3,3 m 16 m
8 ft X-Band 12.5 kW, Version A 0.65 m 1,4 m 7m
25 kW, Version A 1.3 m 2,6 m 13 m
25 kW, Version B 0.9 m 1,8 m 9m
14 ft S-Band 30 kW, Version A 1.3 m 2,6 m 13 m
30 kW, Version B 0.7 m 1,6 m 7.8 m
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Technical Manual 1.6 Safety Switches
1.6 Safety Switches
1.6.1 Man Aloft Switch
The man aloft switch is situated under the Gearbox. If it is switched to

"0", the motor is disconnected from the mains. The Scanner cannot
start to rotate. The Transceiver Electronics Unit is still supplied with
power. See Section 1.6.2.
ztr1_064.jpg
Man aloft switch
1.6.2 HV Supply Switch (Interlock)
The HV supply switch in the Transceiver switches off the high

voltage power supply for the RF electronics, as soon as the
Gearbox or the housing of the bulkhead Transceiver version
is opened. The motor supply and the supply for the other
electronic components are independent of this switch. The
switch has three positions:
1. Gearbox/Transceiver closed; HV electronics supply
3 2 1
switched on.
2. Gearbox/Transceiver opened; HV electronics supply
switched off.
3. Gearbox/Transceiver opened; the switch bolt has been
ztr1_066.jpg
pulled out to supply power to the RF electronics.

Caution! Dangerous voltages and RF radiation. See
Section 1.4 and Section 1.5.
1
2
3
ztr1_149.jpg
HV supply switches (different versions)
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1.6 Safety Switches Technical Manual
18 ED3051G442 / 04 (2008-07)
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Gearboxes and Transceivers 2 Overview
Technical Manual
2 Overview
The following drawing shows the structure of a Radar/MULTIPILOT system. It consists of 3 main groups
of assemblies:
- The Indicator, consisting of the Display Electronics Unit, including a monitor and the Operating Unit
(various versions available).
- The Transceiver, which can be installed in the Gearbox (Version A, "Transmitter Up") or at a
distance from the Antenna Unit in a housing of its own (Version B, "Transmitter Down").
- The Antenna Unit, consisting of the Gearbox and the Scanner.
ztr1_007.eps
Fig. 2-1 System overview
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2 Overview Gearboxes and Transceivers
2.1 Nomenclature Technical Manual
2.1 Nomenclature
The nomenclature shows the versions of Gearbox, Transceiver and Indicator for the Radar 1100 series.
RADARPILOT 1102 / ARPA - 2A8X

CHARTRADAR
MULTIPILOT
Options: Antenna Size:

0 = no options 5 X = 5 ft X-Band
1 = TRACKPILOT 8 X = 8 ft X-Band
Display Size (TFT Monitors): 14S = 14 ft S-Band
PPI Size Transceiver Position:
1 = 180 mm 15.0" (RADARPILOT only) A = Gearbox (up)
2 = 250 mm 17.4" B = Bulkhead (down)
2 = 250 mm 19.0" Transceiver Type:
9 = 340 mm 23.1" 1 = 12.5 kW X-Band
ztr1_166b.eps
Plotting Aid: 2 = 25 kW X-Band

AIS/EPA = Manual (not for MULTIPILOT) 3 = 30 kW S-Band
AIS/ARPA = Automatic
Fig. 2-2 Nomenclature
2.2 Antenna Unit GR3017 / GR3018 / GR3040 / GR3041
2.2.1 Gearbox
ztr1_051.jpg
ztr1_070.jpg
Fig. 2-3 S-Band Gearbox GR3018/GR3041, X-Band Gearbox GR3017/GR3040
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Technical Manual 2.2 Antenna Unit GR3017 / GR3018 / GR3040 / GR3041
The Gearbox has a white coating. Steel parts inside and outside the housing are protected against corro-
sion. Aluminium parts inside the Gearbox are not protected. Nuts, bolts and screws used for the Gearbox
are made of stainless steel (A2).
List of main components:
- Housing with threaded bolts for gear mounting
- Motor with carrier, synchronous belt drive between motor and gear
- Integrated parallel helical gear pair with antenna carrier
- Switch-over contactors for rotary frequency 1 / rotary frequency 2 (only 3-ph Dahlander Motors, 23/
46 rpm, 50 Hz supply (28/46/56 rpm 60 Hz supply)
- Head marker switch, pulse generator for azimuth pulse
- Fuses, integrated man aloft switch
- Performance monitor
- Optional heating
- Connection board for the interconnection between Transceiver electronics unit components and the
Display Electronics Unit
The housing also has facilities for the mounting of the Transceiver (Version A). Parts of the performance
monitor are mounted in the upper part of the Gearbox. The adjustment of the headmarker can be
performed by means of the software. It is not possible to adjust it mechanically.
2.2.2 Scanner GR3004 / GR3021 / GR3009 / GR3021
The Scanners consist mainly of two parts, namely the array and a carrier. The Scanners GR3004Gxxx
and GR3020Gxxx are delivered with the carrier mounted under the array. The carrier must be removed
for the purpose of installation. The carrier for the S-Band Scanner GR3009G090 is mounted on the
Gearbox ex works.
The Scanners GR3004 have been replaced by the Scanners GR3020. The Scanners are fully compatible.
The Scanner GR3009 has been replaced by the Scanner GR3021. The Gearbox must be modified in
case of an exchange.
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2.3 Transceiver Electronics Units NG3028 / NG3029 / NG3040 / NG3041 Technical Manual
2.3 Transceiver Electronics Units NG3028 / NG3029 / NG3040 / NG3041
2.3.1 Enclosures
The Transceiver is available in the following versions:

- Version A (transmitter up)
- Version B (transmitter down)
In version A the Transceiver electronics unit is mounted inside the Gearbox. The housing contains the
Transceiver Electronics Unit. In Version B the Transceiver Electronics Unit is mounted in a separate bulk-
head housing.
Version A offers the best conditions for optimum radar quality, because the most sensitive signals have
to pass through only short cable lengths. The wiring is easier, because all connections between the
Transceiver and the Antenna Unit stay inside the Gearbox and no waveguides have to be installed on
the mast. If it is hardly possible to reach the Gearbox for service and maintenance, version B should be
taken into consideration.
2.3.2 Transceiver Versions
The Transceiver is available with various transmitter performances (nominal power):

Version A (transmitter up):
- X-Band, 12.5 kW
- X-Band, 25 kW
- S-Band, 30 kW
Version B (transmitter down):
- X-Band, 25 kW
- S-Band, 30 kW
2.3.3 Components of the Transceiver
The Transceiver electronics contains the following parts:

- Circulator
- Magnetron
- Modulator
- Receiver
- IF Amplifier
- Transmitter control unit (TCU)
- Mains input unit
- Power supply unit
- RF limiter
Depending on the hardware-version of the transceiver, its components may be slightly different and have
different part-numbers.
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Technical Manual 2.4 Interfaces
2.4 Interfaces
The interfaces for the ship’s sensors and for the connection to other systems are provided by the Display
Electronics Unit. For further information refer to the corresponding technical manuals.
2.5 Compatibility with SAM Electronics Radar / NACOS 1) equipment
From August 2008 on, the advanced performance standards required by international regulations are
implemented in RADAR1100 series.
This has led to a software version 5.x for the electronics units like RADAR1100 and MULTIPILOT1100,
a software version 6.x for the CHARTPILOT1100 and to the enhancement of a number of PCBs like
- The new transceivers NG3040 and NG3041,
- the gear boxes GR3040 and GR3041,
- the new Modulator NG3028G207,
- the new TCU NG3028G221,
- the new IF-Amplifier NG3032G205 and
- the Power-Supply NG3028G202 new Revision 07
Prerequisites are, that the transceiver and its related hardware are
manufactured or upgraded to the correct hardware standard and that
the appropriate software is installed.
RADAR equipment:
The Gearboxes and Transceivers can be used within the following systems:
- RADARPILOT/CHARTRADAR 1000 2)
- MULTIPILOT 10002)
- RADARPILOT 1100
Restriction: Some older versions of pcbs/software cannot be used, see Section 6 on page 99.
- MULTIPILOT 1100
Restriction: Some older versions of pcbs/software cannot be used, see Section 6 on page 99.
- The Transceivers NG3028 and NG3029 can be used with a RADAR 9xxx electronics unit.
Restriction: If one 1000 series Transceiver is integrated in a radar system, than at least one RADAR-
PILOT/CHARTRADAR/MULTIPILOT 1000 Display Electronics Unit must be installed.
NACOS equipment:
Corresponding to the use of the Gearboxes/Transceivers with the different radar versions, they can be
used in NACOS xx-3 (with restrictions), NACOS xx-4, and NACOS xx-5 (with restrictions) systems.
1) Navigation and Command System

2) Only gearboxes GR3017/3018 with transceivers NG3028/3029 are allowed with electronics units series 1000
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2.5 Compatibility with SAM Electronics Radar / NACOS equipment Technical Manual
24 ED3051G442 / 04 (2008-07)
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Gearboxes and Transceivers 3 Installation Recommendations
Technical Manual 3.1 General Recommendations
3 Installation Recommendations
3.1 General Recommendations
3.1.1 Cables
Cable types, cable data, maximum cable length, special instructions for cable laying and connection
details are defined in the Cabling Documents of the corresponding equipment (consisting of schematic
diagram, remarks, cable list and connection diagram).
Interface connections should be discussed and agreed with SAM Electronics.
In order to ensure proper functioning of the equipment, the cable types should be selected according to
the cable lists.
In general, the following points must be taken into account:
- For the cables inside the units (cabinets), an extra length of 1 metre is necessary at each end. If
the height of the unit exceeds 0.5 metre, an extension by 1 m plus the height of the cabinet is neces-
sary.
- The cables must be marked by the electrician at both ends with the cable numbers corresponding
to the SAM Electronics Cabling Documents.
- Where necessary, particular cable glands - marked with letters and/or numbers - are assigned to
the cables.
The identification letters and numbers are stated in the connection diagrams; they are either fixed to
the unit or can be seen from the outline drawings (...BZ or ...MB).
- All cables should be kept as short as possible, especially coaxial cables to minimize attenuation of
signal.
- All outdoor installed connectors (e.g. on coaxial cables) should be waterproof by design to protect
against water penetration into the cable.
- Coaxial cables should be installed in separate signal cable channels/tubes and at least 10 cm away
from power supply cables. Crossing of cables should be done at right angles (90°). Coaxial cables
should not be exposed to sharp bends, which may lead to change the characteristic impedance of
the cable. The minimum bend radius should be 5 times the cable’s outside diameter.
- It must be ensured that all cables - including their screens - are passed into the units in contin-
uous lengths and are not terminated before reaching the destination equipment. This is not valid
for the use of cable glands with grounding inserts.
The cables must be prepared by means of a wire (0.5...1.0 mm², length: 800 mm) as shown in Figure
3-1. The wire has to be connected at the shielding terminal contact.
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3 Installation Recommendations Gearboxes and Transceivers
3.1 General Recommendations Technical Manual
1. 2.
ztr1_153.jpg
ztr1_196.jpg
3. 4.
ztr1_197.jpg
ztr1_198.jpg
Fig. 3-1 Preparation of the cable endings
- When putting the cables into cable glands with grounding inserts, the procedure described must
be followed (see Figure 3-2).
Coaxial cables must be grounded at the cable gland or cable entry of the
housing and at the suitable terminal.
The internal diameter of the sealing ring (1) must be adjusted to the cable diameter. The screen
braiding (2) must be pushed over the anti-cone (3) of the grounding insert. Then the cone (4)
must be put into position. The screen foil (5) must be protected against tearing by means of
26 ED3051G442 / 04 (2008-07)
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insulating tape (6) before it is unwound. Form a kind of wire from the unwound part of the foil
and crimp a connector (7) to the end. The gland must be screwed tight. If the gland is screwed
tight with too much strength, it can happen that the screen braiding is cut.
ztr_176.jpg
7 6 5 4 2 3 1
as short as
possible
ztr_180.jpg ztr_178.jpg
Fig. 3-2 Cable glands with grounding inserts
- With the use of cable glands without grounding inserts, the screen braiding inside the unit must
be plaited to form a "pigtail", terminated by a cable terminal, and connected to the prescribed
grounding terminal. It must be ensured that the grounding lead is kept as short as possible.
- In the case of a unit whose cable inlet consists of a hole with brackets attached on the inside
and outside, the cable must be dressed as shown in Figure 3-3.
- With multicore cables, it is useful to strip down and lace the single wires according to the terminal
sequence.
- Receptacle-type cable terminals included in the delivery must be crimped to the connecting leads
by means of a suitable pair of AMP pliers. If a terminal board of a unit has no tabs for the above-
mentioned receptacles, other suitable cable terminals must be used.
- Existing cable grippers in the units must be used.
- All cable connections must be carefully checked after completion of the cable work and all cable
screens must be grounded via the shortest possible connections - if not stated otherwise in the
Cabling Documents/Connection Diagram.
- All cables must be secured by means of suitable clamps (pull-relief) before entering the units.
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- When soldering stripped coaxial cables to connectors, it must be ensured that the central
conductor and the screening do not produce a short circuit. A short-circuit check after installation is
advisable.
- It must be ensured that cables do not block any moving parts within a unit.
- Stuffing tubes exposed to the open air must, without fail, be sealed with compound.
- Power leads must be protected by "slow-blow" fuses according to their cross section.
Brackets
Metal clamp inside Installation cables

FMGCH, FMKHC, MGCH etc.
35+5 Screen braid laid back over outer sheathing;

contact with the brackets via metal clamp
Metal clamp outside

ztr1_072.gif
Fig. 3-3 Cable inlet consisting of a hole with brackets
3.1.1.1 Maximum Cable Length
Coaxial S-Band Cable/Flexible X-Band Waveguide

The maximum length of these cables is defined by the cable sets (usually 25 m). See Section 3.1.1.3 and
Section 3.1.1.4.
Coaxial Cable for TVA Signal

The maximum length of the TVA cable must not exceed 300 m. For a length of more than 150 m, see
the hints in Section 4.5.5 on page 82.
CAN Bus
The CAN bus cabling of CAN 0 must not exceed a length of 500 m between the termination resistors
when a cable FMGCH or FMKHC is used.
The CAN bus cabling of CAN 1 must not exceed a length of 100 m.
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3.1.1.2 Cable Sets
The cable sets for the waveguide/coaxial cables are described in Section 3.1.1.3 and Section 3.1.1.4.
Cable sets for the standard-cables of X/S-Band installations are no longer available. The cables can be
ordered in the required length by means of the following order numbers:
Cable type Order No. of the individual items

Coaxial Cable
Draka 1.0/4.8 AF FRNC 300006082
(former TELASS 100 PE) (535-1708)
Cable (8-core)
FMKHC 4x2x0.75 300005306
(former FMGCH) (535-4461)
3.1.1.3 S-Band Coaxial Cable
The coaxial S-Band cabling only has to be performed for the bulkhead version of the Transceiver.
The installation material is not part of the standard scope of delivery, but it can be obtained by special
order. It consists of the coaxial cable with clamps and one set of connectors with accessories:
Waveguide Set for S-Band 10 m,

Version B (bulkhead) Quantity Order No. of the individual items
Set VS3034G022, order No. 2774772
Coaxial S-Band Cable, Flexwell 5/8" CU 2Y 50  10 m 5359703
FMGCH, FMKHC 7x2x0.75 30 m 5354462
Clamp 19 390002164
Coax Cable Connector 2 5329810
Coax Adapter right-angled 1 5329802
Bellows 1 5502186
Hose Clip 1 5361309
Hose Clip 1 5361311
Sealing Compound AWN142-P4 5680706

VS3034G023, order No. 2774773
FMGCH, FMKHC 7x2x0.75 30 m 5354462
Clamp 29 390002164
Bellows 1 5502186
Hose Clip 1 5361309
Hose Clip 1 5361311
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VS3034G024, order No. 2774774
FMGCH, FMKHC 7x2x0.75 30 m 5354462
Clamp 39 390002164
Bellows 1 5502186
Hose Clip 1 5361309
Hose Clip 1 5361311

VS3034G025, order No. 2774776
FMGCH, FMKHC 7x2x0.75 30 m 5354462
Clamp 49 390002164
Coax cable connector 2 5329810
Coax adapter right-angled 1 5329802
Bellows 1 5502186
Hose clip 1 5361309
Hose clip 1 5361311
Sealing compound AWN142-P4 5680706
30 ED3051G442 / 04 (2008-07)
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Laying the S-Band Coaxial Cable (overall diameter: 23 mm)
SAM
200 mm
wind 90°
700 mm
Clamps 390002164
Start at the Gearbox!
Do not deform the coaxial

cable with the clamps
Bending radius >200 mm

r
500 mm
Avoid horizontal laying!
Protect from mechanical damage!

(conduit or u-shaped metal cover) Standard cable
gland M36x2
Deck Caution! Do not
crush the cable!
S-Band Transceiver
(Version B, Bulkhead)
z_ig_063.eps
Mounting of the Coax Connector

1. Tools and material needed:
- Measuring tape (mm graduations)
- Cable knife
- Fine-toothed saw
- Wooden pintle, cleaning material
- Flat file
- Open-ended spanner (jaw opening 24 mm and 30 mm)
- Screwdriver blade width 5.5 mm
1. When the coax connector is being mounted, moisture must not be allowed to get into the cable or
connector - such moisture may lead to disturbances on the radar display in the form of a bright
center spot and a reduced range capability.
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2.
22 mm
check/
adjust
z_ig_084.jpg
Nozzle for "Plast 2000" Cover-screw for gas inlet, do not remove!
Fig. 3-4 Preparation of the connector
3. Saw off the cable at right angles. Do not deform the cable!
Rain, moisture
Chips, dirt
30 16 +2
Carefully pull out

z_ig_085.jpg
the helix against its

sense or rotation.
Cut off 10 (+5) mm
10 +5 and push back into
former position
Mark circularly 38 ±0.5
Remove chips and

filling material!
Debur
z_ig_086.jpg
Fig. 3-5 Preparation of the cable end
32 ED3051G442 / 04 (2008-07)
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4. Push the bellows with the clip onto the cable

before mounting the connector!
5.
1. Screw the connector
onto the cable until
the circular marking
is reached.
2. Tightly screw the
smaller part into the
larger part of the
connector (30 Nm).
3. Screw the tube with
"Plast 2000" into the
nozzle and fill with
"Plast 2000" until it
emerges at the vent
on the opposite side.
Close this vent and
continue with filling
until "Plast 2000"
emerges constantly
between the cable
sheath and the
connector.
Remove the tube
and close the nozzle.
3.
Discharge
1. 2.
30 Nm
z_ig_087.jpg
Vent
Fig. 3-6 Assembling the connector and sealing with "Plast 2000"
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Connecting the Coax Connector to the Gearbox
1. The coax connector (1) and the bellows (2) must already have been mounte
on the S-Band coax cable.
ztr1_032.gif
2. Screw the coax connector onto the rotary joint.

3. Push the bellows up and fix it by means of the clips (3) and (4).
Fig. 3-7 Connecting the coax connector
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3.1.1.4 X-Band Flexible Waveguide
The waveguide installation only has to be performed for the bulkhead version.
The waveguide must be laid as straight as possible. Inside the Gearbox, the waveguide can be rotated
through 90° if this will make installation easier. Normally, flexible waveguide of type FLEXWELL E100
CU2Y is used. The installation material is not part of the standard scope of delivery, but it can be obtained
by special order. The following waveguide sets are available:
Waveguide Set for X-Band, 10 m,

VS3034G018, order No. 2774763
Flexwell Waveguide E100 CU 2Y 10 m 5351658
FMGCH, FMKHC 7x2x0.5 30 m 5354462
Plane Fitting 1 5524060
Choke Fitting 1 5524061
Cheese head screw 8-32NC for fittings 8 5459929
Clamp 19 5360997
Clamp Insert 19 5369053
Membranes 2 7300405
Sealing Compound Plast 2000 5680716

VS3034G019, order No. 2774767
FMGCH, FMKHC 7x2x0.5 30 m 5354462
Clamp 29 5360997
Membranes 2 7300405

VS3034G020, order No. 2774769
FMGCH, FMKHC 7x2x0.5 30 m 5354462
Clamp 39 5360997
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VS3034G020, order No. 2774769
Membranes 2 7300405

VS3034G021, order No. 2774770
FMGCH, FMKHC 7x2x0.5 30 m 5354462
Clamp 49 5360997
Membranes 2 7300405
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Laying of the Waveguide

The type of waveguide is normally Flexwell E100.
SAM
Clamps 5360997 with

inserts 5369053
Do not deform the

waveguide with the clamps
Start at the Gearbox!
300-500 mm
The PVC membrane must

be inserted at both ends
of the waveguide.
Bulkhead gland
535-1697 or
Never horizontal! Deck tube 76.1x6.3
with sealing
compound
r
X-Band Transceiver
(Version B, Bulkhead)
Radius >300 mm ("broad side")
z_ig_062.eps
Radius >600 mm ("narrow side")
Fig. 3-8 Laying of the X-Band flexible waveguide
Installing the Waveguide Fittings

1. Tools and material needed:
- Small hammer
- Fine saw
- 3 mm hexagon wrench key
- Flat-nosed pliers
- Cable stripping knife
- Fine file
- Measuring rule or calliper gauge
- Insulating tape / adhesive tape
2. When the fittings are being installed, moisture must not be allowed to get into the waveguide or into
the fittings. Such moisture would cause faults in the radar picture - a bright centre and a reduced
range.
It is also important to ensure that no metallic shavings produced by sawing or filing, or any other
foreign bodies, fall into the waveguide.
Note:
The ends of the waveguide have to be sealed until the final connection to Gearbox and/or Trans-
ceiver is made.
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3. The procedure for installing the choke fitting is slightly different from the procedure for the plane
fitting. The differences are described in the following instructions and drawings.
SAM
Choke fitting
Plane fitting,
start here!
Choke fitting
z_ig_073.jpg
Plane fitting
Transceiver
Plane fitting Outer groove for O-ring seal Choke fitting
Fig. 3-9 Positioning of plane fitting and choke fitting
4. Before installing the fitting, dismantle it. Remove the four hexagon screws.
z_ig_074.jpg
z_ig_075.jpg
Plane fitting Choke fitting
Fig. 3-10 Fittings
5. Prepare the upper end of the waveguide (plane Plane fitting: Choke fitting: X
fitting) as shown in Figure 3-11. Cut off 32 mm of X = 32 mm X = 35 mm
the insulation.
Strip off 35 mm of the insulation of the lower end
of the waveguide (choke fitting) as shown in
Figure 3-11.
z_ig_076.jpg
Fig. 3-11 Dismantling the waveguide end
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6. Push the cable bushing (black) over the

waveguide and prepare the end of the
waveguide as shown in Figure 3-12.
z_ig_077.jpg
Fig. 3-12 Preparation of the waveguide end
7. Using a pair of flat-nosed pliers, bend the
projecting end of the corrugated tube outwards
and form it into a flange shape by means of a
small hammer. When doing this, work anticlock-
wise. A flat contact-surface must be created
here. If necessary, rework the surface with the
z_ig_089.GIF
aid of a fine file.
When doing this, hold the surface so that it is
facing downwards, to prevent any filings from
falling into the waveguide. Fig. 3-13 Forming a flange
Rain, moisture
Chips, dirt
z_ig_081.jpg
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Poor flange Sealing damaged by

a poor flange
Gaps must be
avoided!
Flange too long!
z_ig_080.jpg
Flange is OK Sealing is OK
z_ig_082.jpg
z_ig_081.jpg
Fig. 3-14 Making a flange
8. The filling nozzle for the "Plast

2000" must be open. If there is
sheath of the waveguide under
the nozzle, the fitting has been
mounted incorrect.
z_ig_078.jpg
z_ig_079.jpg
Fig. 3-15 Filling nozzle
9. Now securely screw the base of the fitting together with the sealing for the fitting by means of the
four flange screws and spring washers and the bushing of the waveguide.
z_ig_090.gif
Plane fitting Choke fitting
Fig. 3-16 Assembling (X-Band)
40 ED3051G442 / 04 (2008-07)
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10. Before injecting the "Plast 2000",

experience has shown that it is
best to bind the end of the
waveguide bushing with insulating
tape or adhesive tape at the
region of transition to the
waveguide. Pierce the insulating
Gas injection
tape or adhesive tape between nozzle, must be
the waveguide and the waveguide closed by means of
bushing on the side opposite to the inserted copper
the filling nozzle. sealing platelet
11. The opened tube of "Plast 2000"

must be screwed into the filling
nozzle. The space between the
waveguide bushing and the
waveguide must be filled carefully
until the "Plast 2000" starts to
emerge from the pierced hole in
the insulating tape. One tube is
sufficient for two fittings.
12. The O-ring seal belonging to the
z_ig_083.jpg
Pierce a hole in the

choke fitting must be kept in a insulating tape.
safe place, ready for further instal-
lation of the waveguide.
Fig. 3-17 Sealing with "Plast 2000"
3.1.2 Basics about X- and S- Band Waveguides
The waveguides connect the antenna to a distant transceiver in the so-called "bulkhead"-installation. (See
chapter 2.3.2 for details). Waveguides are a special kind of high-frequency cable that require special
attention regarding installation and handling. See 3.1.1 "general recommendations / cables" for details.
Waveguides for X- band and S- band are available in lengths of 10,15,20 and 25 meters ex works.
As a basic principle, all waveguides shall be kept as short as possible. Depending on the length of the
waveguides, the output intensity of the radar transceiver will be attenuated and the close-range detection
of targets will be influenced.
Attenuation:
For example, for the X-band flexible waveguide, the transmitted energy experiences an attenuation of
1.1 dB per 10 meters, the recieved target signal experiences the same attenuation. That means, the radar
signal is attenuated close to the half of the originally transmitted amount after 10 meters.
Close-range detection:
In high-frequency installations it is usual that a small part of the radar pulse will be reflected inside of the
antenna and will run back to the transceiver where it will be detected by the receiver. This reflected pulse
takes even more time to run back the longer the waveguide is. The reflected pulse may disturb the
receiver from detecting echoes which represent close-range radar targets, especially in the short ranges
of the radar. (On the other hand, the reflected pulse gets weaker the longer the waveguide is, but it can
still be much stronger than echoes of some radar targets!).
For these reasons, it is highly recommended to have the waveguides as short as possible, docking radars
should better be of the so-called "aloft"-installation where the transceiver is connected directly to the
antenna.
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3.1.3 Electronics Units
Dimensions, weights, spaces required for service and maintenance and special installation instructions
are stated in the outline drawings and installation drawings of the corresponding unit. In general, the
following points also apply:
- The useful life of the components of all electronics units (display units, pulse generators, Trans-
ceivers etc.) generally decreases with increasing ambient temperature; it is therefore advisable to
install such units in air-conditioned rooms. if there are no such facilities - e.g. deckhouse or space
near or below the water line - these rooms must at least be dry, adequately ventilated and kept at a
suitable temperature in order to prevent the formation of condensation inside these units.
- With most electronic units, cooling takes place via the surface of the casing.
The cooling must not be impaired by partial covering of the unit as a result of insulation (if any) of
the room (the wall on which the casing is mounted), or by installation of the unit in a confined
cabinet.
Furthermore, the distance from the ceiling and the floor or from a unit situated underneath must be
at least 500 mm.
- For service purposes, a power socket (AC 220/230 V) and adequate lighting are necessary in the
vicinity of each electronics unit.
- In the area of the wheel house, the distance of each electronics unit from the magnetic standard
compass or the magnetic steering compass must not be less than the permitted magnetic protec-
tion distance.
This distance is measured from the centre of the magnetic system of the compass to the nearest
point on the corresponding unit concerned.
- Units which are to be used on the bridge wing must be installed inside the "wing control console" -
protected against the weather - if they do not at least correspond to the enclosure type IP 56. In
order to avoid misting of the viewing screen, 25 ... 50 W console-heating (power depending on the
volume) is recommended.
- When selecting the site of a unit, the maximum cable lengths have to be considered according to
the notes in the cabling documents (remarks, cable list).
- The accessibility for maintenance and service (stated in the outline drawings or installation draw-
ings) must be considered.
- The impairment of a digital read-out or a display screen by direct light from lamps or the sun must
be avoided. Rear windows must be blacked out by means of roller blinds or venetian blinds.
- Disturbing reflections on the screen of a display caused by pilot lamps and illuminated signs must
be prevented by suitable measures (screening or relocating).
- When a unit is being installed, the base, floor or bulkhead must be checked to ensure that it is
flat in order to avoid twisting of the unit when the fixing screws are tightened, because such twisting
would impair mechanical functions. Any unevenness should be compensated for by means of
spacing-washers.
- The grounding screws of the units must be connected to the body of the ship (ground); the wire
used should have a cross sectional area of at least 6 mm.
Aboard fibreglass (GRP) vessels, a "grounding network" with a high conductance - taking into
consideration the working frequencies of the other equipment - must be provided in order to achieve
satisfactory EMC (electromagnetic compatibility).
42 ED3051G442 / 04 (2008-07)
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- In the interests of safety during maintaining or servicing, the shipyard should provide a common
isolating switch or circuit breaker (in conjunction with a contactor, if necessary) for all intercon-
nected equipment.
- Transportation damage, even if apparently insignificant at first glance, must immediately be exam-
ined and be reported to the freight carrier. The moment of setting-to-work of the equipment is too
late, not only for reporting the damage but also for the supply of replacements.
- The equipment should never be switched on by the electricians who did the installation work
- not even just for a moment - never!
This is a job for the authorised SAM Electronics service engineer.
- After hand-over of the equipment in good operating condition to the customer, the Installation
Report (Annex of the Warranty Certificate) should be filled in completely and then forwarded to SAM
Electronics as proof of such fulfilment. It is important that these requirements be fulfilled in order to
avoid the risk of losing the warranty.
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3.1.4 Radar Scanner, General Hints
Dimensions, weights and special installation instruc-

tions are stated in the outline drawings and installation
drawings and in Section 3.2.
The navigational value of radar equipment on board a
vessel is significantly influenced by the choice of the
location of the radar Scanner.
The rules for the prevention of accidents issued by the
competent authorities must be taken into account when
designing the radar mast. A convenient arrangement
must be ensured which will enable the Antenna Unit to
be serviced or repaired later without the need for a
crane or stagings. In this way, accidents can be
avoided and service costs can be cut.
Different flag state authorities or classification societies
may have additional rules regarding the design of the
antenna mast or the installation of antennas or the
operation of radar equipment in a harbour. Please
obtain their advice. For ships sailing under the German
flag, the conditions for the installation of radio location
systems and integrated navigation systems of the
Bundesamt für Seeschiffahrt und Hydrographie
(Federal Maritime and Hydrographic Agency - German
ztr1_026.jpg
abbreviation "BSH") must be fulfilled.

1. Radar Scanners with automatic radar plotting aids Example of an antenna mast
(ARPA’s) must, as a matter of principle, be effec-
tive over a horizontal arc of 360° without obstruc-
tion.
2. If, for non-ARPA equipment, an unhindered all-round view cannot be achieved, blind sectors on
which ghost echoes occur will just have to be regarded as unavoidable. Shadow effects in the sector
from 355° to 5° must be avoided under all circumstances and they are generally not allowed in the
sector from 225° to 135° either.
3. Normally, the radar Scanner will be sited on the centre line of the vessel, above the height of signif-
icant obstacles. The difference in height between significant obstacles (e.g. funnel, traverse etc.) and
the radar Scanner should be at least 1/20 of the distance apart, but not less than 1.5 m for distances
of less than 30 m.
4. With very high cranes or traverses which are within the sector mentioned in 2., the radar Scanner
must be located off the centre line. The difference between the lateral distances of the obstacle (e.g.
crane, mast or king post) and of the radar Scanner from the centre line must be at least 1/10 of the
distance apart.
5. Smooth, even surfaces and three-dimensional inner corners of superstructures act as reflectors if
they are located within the radiation area of the radar Scanner (vertical approx. ±11°). they cause
ghost echoes on the screen. in the immediate vicinity of the Scanner (0..30 m) disturbing reflections
can even appear within a vertical angle of ±25° and over. such unwanted reflectors are mainly
traverses, derricks, rear bulkheads of crow’s nests, brackets of platforms and lamp holders, as well
as rail stanchions, ladder uprights made of flat section steel and rungs. they must be made as inef-
fective as possible by modification of their position or their design (bending, rounding off etc.) or by
44 ED3051G442 / 04 (2008-07)
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the use of tubular material.

For simple assessments of surfaces that might cause reflections, the laws of optics ("angle of reflec-
tion is equal to angle of incidence") can be applied.
6. The vertical clearance from a platform above a slotted array must be at least 1 m. if this recom-
mended minimum clearance cannot be achieved, the Scanner, at least the one for the ARPA, must
be arranged on the highest point ("above all").
7. It is not advisable to mount the radar at the funnel or within range of concentrated exhaust gases,
as these lead to early destruction by corrosion.
8. If the radar Scanner is located in the vicinity of the funnel or of the exhaust pipes, the opening(s)
should be pointing in a direction such that the antenna (the centre of the slotted array) cannot "look"
into the pipe(s). This means that exhaust pipes must either be bent sternwards or cut so obliquely
that the openings are concealed.
9. Down-leads of radio antennas must not run in the vicinity of the radar antenna, its waveguide or coax
feeder. The distance should be at least 5 m or the down-leads must be shielded by separate pipes.
10. The radar mast must be fitted with a walkable platform with a railing. This is especially important if
the dimension of the Scanner array exceeds 5 feet or if two antennas are installed.
With smaller Scanners and in special cases, the mast must be equipped at least with a foot ring, an
intermediate ring and a back safety ring.
11. The antenna mounting flange (top plate) must in all cases be welded on parallel to the CWL. It must
be absolutely even in order to avoid breaking of the antenna housing when tightening the nuts. The
mounting plate must correspond to the demands of the outline drawings in Section 11. Especially
the specification for the evenness must be kept. The mounting plate is not part of the standard scope
of delivery, but it can be obtained from SAM Electronics by special order.
12. Re-sealing
Water-tight seals, O-rings, silicone sealing compound, etc. must be refitted after an outdoor housing
has been opened for any reason.
13. A radar mast made from a pipe should be stayed in accordance with its length by means of wire
ropes. Rigid pipe stayings are unsuitable as they usually transmit harmful "hard" vibrations to the
Antenna Unit.
14. If two radar Antenna Units are installed one above the other, the vertical distance between them
must not be less then 1 m (between the closest edges).
15. The clearance of the Scanner array above railings and between a mast and the end of the Scanner
must be at least 500 mm for safety reasons.
16. The radar Antenna Unit and the coaxial cables or waveguides must be assembled according to the
instructions given in this manual.
ED3051G442 / 04 (2008-07) 45
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ztr1_031.eps
ztr1_082.gif
ztr1_083.gif
Fig. 3-18 Antenna arrangement/positioning
46 ED3051G442 / 04 (2008-07)
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3.1.5 Transceiver
In the case of a bulkhead Transceiver:

The site of a radar Transceiver depends on its waveguide or coax cable connection to the Scanner. The
ideal site would therefore be in the immediate vicinity of the radar mast. If such a position is not possible,
the path of the waveguide or coax connection with the superstructure should be planned to be as short
and as straight as possible in order to avoid unnecessary attenuation of transmitted energy and radar
echoes.
The upper edge of the bulkhead Transceiver should be positioned at a height of about 1500 to 1800 mm
above deck but at least 600 mm below deckhead.
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3.2 Specific Recommendations Technical Manual
3.2 Specific Recommendations
3.2.1 Recommendations Concerning the Installation of the Antenna Unit
ztr1_044.jpg
ztr1_043.jpg
Fig. 3-19 X-Band Antenna Unit, S-Band Antenna Unit
For general recommendations concerning the positioning of the antennas, the construction of antenna
masts and the plates for the Gearbox, see Section 3.1. and Section 11.
IMPORTANT
1. The Gearbox should be installed in such a way that the cover is facing astern to protect it
from weather and from spray.
2. See the hints for grounding in Section 10. The Gearbox is equipped with a threaded bolt on
the underside.
3. If the Antenna Unit shall be installed on a tiltable mast, it is advisable to contact the manu-
facturer for further information.
4. Do not mount the Gearbox on a lying mast! The bearings and seals are not prepared for a
90°-turned (horizontal) position. Install the Gearbox in an upright position.
5. If an additional mains switch for the Gearbox is installed, it must be taken into consideration,
that an optional heating is switched off as well. At extremely low temperatures the motor may
not start and get damaged if the heating did not work beforehand.
The positioning of the Antenna Unit depends on the ship type. Hints for the positioning and construction
of an antenna mast are given in Section 3.1, I n s t a l l a t i o n R e c o m m e n d a t i o n s and Section 11, O u t l i n e
Drawings.
48 ED3051G442 / 04 (2008-07)
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Technical Manual 3.2 Specific Recommendations
3.2.2 X-Band Antenna Unit
3.2.2.1 Installation of the X-Band Gearbox

ztr1_040.jpg
ztr1_042.jpg
Fig. 3-20 X-Band Gearbox flange and Scanner GR3004 (bottom) with holder
The Antenna Unit is delivered in a dismantled condition. It must be assembled according to these instruc-
tions. The Scanner and the Gearbox of a version B/Transceiver down system are marked as belonging
together as a pair, because the standing wave ratio has been adjusted in the assembled condition ex
works. If one of the components (Scanner or Gearbox) has to be exchanged, the adjustment must be
checked in accordance with the instructions of the technical manual or in cooperation with the manufac-
turer.
Lifting of the Antenna Unit

The Gearbox can be hoisted with the aid of a crane. For this purpose, eyes are provided on the top of
the Gearbox casing so that shackles can be attached. It is not permissible to move the complete Antenna
Unit by means of ropes which are fixed to the Scanner.
Do not lift the Antenna Unit by means of a rope fixed to the Scanner! Always lift the
Antenna Unit by means of chains or ropes which are fixed to the three eyes of the
Gearbox.
Bolts and Self-locking Nuts

To enable the Gearbox to be fixed to the top plate of the mast, corrosion-proof bolts have been fitted.
These bolts must not be unscrewed and must not be replaced by different bolts. In addition to this, the
self-locking nuts provided must also be used in order to ensure reliable fastening.
NOTE
The Gearbox must be mounted on the mounting plate by means of the self locking nuts and the washers
which are delivered with the Gearbox. Do not use the nuts of the transportation pallet. Do not use
further washers or rubber rings that have not been delivered with the Gearbox.
ED3051G442 / 04 (2008-07) 49
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NOTE
Before the nuts are tightened, it must be ensured, that the Gearbox rests on the mounting plate at all
fixing points. Any gaps between the Gearbox and the mounting plate must be filled out by means of the
enclosed washers.
Gearbox
Top plate
Antenna mast
ztr1_022.pdf
Fig. 3-21 Levelling of uneven mounting plates
The self-locking nuts are lubricated with grease ex works. This grease must not be
removed! If there is no grease on the self locking nuts, the nuts or the bolts must be
lubricated by means of lubricating grease or oil, before the nuts are screwed on. Sili-
cone paste must not be used!
The self-locking nuts must be tightened with a torque of 85 Nm. If the bolt turns with
the nut, it must be tightened from inside the Gearbox with 100 Nm, before the nut is
tightened. There must not be any clearance between the nut and the Gearbox and
between the head of the bolt and the Gearbox after the nut has been tightened.
The top plate GR3004T113 can be manufactured in accordance with the drawings in Section 11, O u t l i n e
D r a w i n g s , or can be ordered under the order No. 732376.
3.2.2.2 Installation of the X-Band Scanner
NOTE
Each Scanner of the type GR3020G150 or GR3020G160 is delivered with a holder that belongs to the
Scanner. The Scanner has been adjusted with its specific holder. It is not permissible to mount a Scanner
with the holder of a different Scanner. The Scanner and its holder are marked with the same serial
number. The serial number of the Scanner and of the holder are engraved in the surface of the holder
and of the Scanner.
50 ED3051G442 / 04 (2008-07)
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The assembling procedure (see Figure 3-23):

1. After unscrewing the eight (8" Scanner) or four (5" Scanner) screws M8x16 (4), separate the
Scanner (1) from the holder (2). Smear the threads of the screws with silicone paste (order No. 567-
0152). Store the screws and washers in clean conditions until they are used.
IMPORTANT
The coupling pin (3) must not get damaged or bent.
Water (rain) must not be allowed to pour into the screw holes (7) during the installation.
2. Smear the threads of the six screws M10x20 (10) with silicone paste. Store the screws and washers
in clean conditions until they are used.
3. Smear the area (6) and the sealing ring (5) on the mounting flange of the Gearbox with silicone
paste. Fill the screw holes (7) and the small channel in which the screws are situated with silicone
paste.(If it is not already filled with grease ex works)
IMPORTANT
Silicone paste must not be allowed to get onto the surface of the rotary joint (8) or
onto the coupling pin (3).
Do not use any other kind of sealant between the holder and the Scanner.
Put the holder (2) carefully onto the mounting flange (11) without damaging or bending the coupling
pin (3). Pay attention to the position of the position pin.
Secure the holder by means of the six screws (10) and washers. Tighten the screws uniformly. Maximum
tightening torque = 50 ± 4 Nm.
4. With silicone paste smear the sealing rings (9) and (12) situated on the top side of the holder (2)
and smear the non-painted surface.
5. Centre the Scanner and put it onto the holder. Pay attention to the coupling pin!
6. Secure the Scanner by means of the eight screws (4) and washers. Tighten the screws uniformly.
Maximum tightening torque = 26 ± 2 Nm.
ztr1_158.gif
Fig. 3-22 Length of the coupling pin of the X-Band Antenna Unit
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ztr1_041.gif
Fig. 3-23 Assembling the X-Band Scanner
3.2.2.3 S-Band Antenna Unit

ztr1_045.jpg
ztr1_046.jpg
Fig. 3-24 S-Band Gearbox with carrier, carrier under Scanner
The Antenna Unit is delivered in a dismantled condition, with the Gearbox and the Scanner all separate.
The Antenna Unit must be assembled according to these instructions.
The Scanner and the Gearbox of a Transceiver down system are marked as belonging together as a pair,
because the standing wave ratio has been adjusted in the assembled condition ex works. If one of the
components (Scanner or Gearbox) has to be exchanged, the adjustment must be checked in accordance
with the instructions of the technical manual or in cooperation with the manufacturer.
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Lifting of the Antenna Unit

The Antenna Unit can be hoisted with a crane. For this purpose, three eyes are provided on the top of
the Gearbox so that shackles can be attached. It is not permissible to move the complete Antenna Unit
by means of ropes which are fixed to the Scanner.
Do not lift the Antenna Unit by means of a rope fixed to the Scanner! Always lift the
Antenna Unit by means of chains or ropes which are fixed to the three eyes of the
Gearbox.
Bolts and Self-locking Nuts

To enable the Gearbox to be fixed to the top plate of the mast, corrosion-proof bolts have been fitted.
These bolts must not be unscrewed and must not be replaced by different bolts. In addition to this, the
self-locking nuts provided must also be used in order to ensure reliable fastening.
NOTE
The Antenna Unit must be mounted on the mounting plate by means of the self locking nuts and the
washers which are delivered with the Antenna Unit. Do not use the nuts of the transportation pallet.
Do not use further washers or rubber rings that have not been delivered with the Antenna Unit.
NOTE
Before the nuts are tightened, it must be ensured, that the Gearbox rests on the mounting plate at all
fixing points. Any gaps between the Gearbox and the mounting plate must be filled out by means of the
enclosed washers.
Gearbox
Top plate
Antenna mast
ztr1_022.pdf
Fig. 3-25 Levelling of uneven mounting plates
The self-locking nuts are lubricated with grease ex works. This grease must not be
removed! If there is no grease on the self locking nuts, the nuts or the bolts must be
lubricated by means of lubricating grease or oil, before the nuts are screwed on. Sili-
cone paste must not be used!
The self-locking nuts must be tightened with a torque of 120 Nm. If the bolt turns
with the nut, it must be tightened from inside the Gearbox with 140 Nm, before the
nut is tightened. There must not be any clearance between the nut and the Gearbox
and between the head of the bolt and the Gearbox after the nut has been tightened.
The top plate GR3013T001 can be manufactured in accordance with the drawings in Section 11, O u t l i n e
D r a w i n g s or can be ordered under the order No. 738133.
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3.2.2.4 S-Band Scanner
Depending on the version of the Scanner, the rotary joint is fixed in the flange (1) of the coaxial tube
(current version of the Scanner, GR3021G090, Transceiver Down), inside the Gearbox (current version
of the Scanner, GR3021G090, Transceiver Up) or in the Scanner (former version of the Scanner,
GR3009G090).
There are also two different versions of the Gearbox. To be able to use the current version of the
Scanner, the Gearbox must be of the version with the rotary joint inside (Transceiver up) or below (Trans-
ceiver down) the housing.
The mounting of the Scanner is different for both types of Scanners:
Mounting the S-Band slotted Scanner GR3021G090 (Current Version)

Before mounting the Scanner:
Transceiver down:
1. Remove the bellows at the coaxial cable Transmitter down Transmitter up
connector, if mounted.
2. Untighten the headless screws in the flange. Headless screws
3. Proceed with step 4.
Transceiver up:
1. Open the Gearbox. Disconnect the coaxial cable
from the Transceiver unit and swing out the
holder with the Transceiver Electronics Unit.
2. Untighten the headless screws in the flange.
ztr1_667.jpg
ztr1_668.jpg
Rotary Joint
3. Proceed with step 4.
For Transceiver up and Transceiver down:
4. Pull down the rotary joint as far as possible. The
connector of the coaxial tube (3) must be
positioned about 20 mm below the upper
surface of the hollow shaft.
20 mm
5. See Figure 3-26. Smear the sealing ring (7) of
the holder (5) with silicone paste (order No.
567-0152). Do not use any other sealant
between the holder and the Scanner.
After mounting the Scanner:
6. Before putting the Scanner on, align it as accu-
ztr1_666.jpg
rately as possible relative to the holder. The (3)

profiles (6) on the underside of the Scanner
(see Figure 3-26) make it easier to centre the Scanner.
IMPORTANT NOTE:
Newer versions of the holder are asymmetrically. The sticker on the holder shows
the correct position of the Scanner (protrusion of the holder below the back of the
Scanner).
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7. Secure the Scanner by means of the eight screws M10x30 (1) and washers, smeared with silicone
paste. Maximum tightening torque = 50 ± 4 Nm.
(2) Front
(4) (6)
(7) (3)
(1)
Back
(5) Back
Front
ztr1_669.jpg
Fig. 3-26 Mounting the S-Band Scanner GR3021G090
8. The coaxial tube must be pushed upwards into the Scanner. When the connector at the upper end
of the coaxial tube noticeable gets hold in the counterpart in the Scanner, it must be screwed into
the Scanner by hand.
9. Transceiver down: Transceiver down Transceiver up
Two flattenings have been
milled in the coaxial tube. The
tube can be tightened in the
Scanner by means of a 19 mm
spanner.
Transceiver up:
The coaxial tube must be tight-
ened by means of a hexagon
socket head wrench (belongs
ztr1_659.jpg
ztr1_670.jpg
to the scope of delivery) or

something similar which can be
inserted in the holes of the ring
above the rotary joint.
10. The headless screws in the flange must be tightened.
11. Transceiver down: The coaxial connector and the bellows must be mounted.
Transceiver up: The carrrier with the transceiver electronics unit must be closed. The flexible coaxial
cable must be connected.
Mounting the S-Band slotted Scanner GR3009G090 (Transceiver Up and Down, Former Version)
1. Smear the centering lug (2) of the Scanner (4) and the sealing ring (7) of the holder (5) with silicone
paste (order No. 567-0152). Do not use any other sealant between the holder and the Scanner.
2. Before putting the Scanner on, align it as accurately as possible relative to the holder. The profiles
(6) on the underside of the Scanner (see Figure 3-24) make it easier to centre the Scanner.
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Important!
The coupling pin (3) must not get damaged or bent.
NOTE:
Newer versions of the holder are asymmetrically. The sticker on the
holder shows the correct position of the Scanner (protrusion of the
holder below the back of the Scanner).
3. Secure the Scanner by means of the eight screws M10x35 (1), smeared with silicone paste.
Maximum tightening torque = 50 ± 4 Nm.
ztr1_049.gif
Fig. 3-27 Mounting the S-Band Scanner GR3009G090

ztr1_159.gif
Fig. 3-28 Length of the coupling pin of the S-Band Antenna Unit
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3.2.3 Gearbox Cable Entries
The Gearboxes are equipped with four bushings on the underside. It is advisable to use the bushings as
shown Figure 3-29.
4
7
1 2 3
6 5
ztr1_099.gif
Fig. 3-29 Cable entries
X-Band Gearbox with positioning of the connec-

No. S-Band Gearbox tion board as shown in Figure 4-7 on page 66
1 3-ph mains for motor CAN Bus input
2 1 ph mains (for electronics unit) Video (coax) (See the warning below.)
3 CAN Bus input 3-ph mains for motor
4 Video (coax) (See the warning below.) 1 ph mains (for electronics unit)
5 Waveguide inlet for version B (closed in version A) Waveguide inlet for version B (closed in version A)
6 Man aloft switch Man aloft switch
7 Grounding bolt Grounding bolt
CAUTION
The coaxial cables must be grounded at the cable gland
AND at the appropriate terminal. See Figure 3-2 on page
27.
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58 ED3051G442 / 04 (2008-07)
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Gearboxes and Transceivers 4 Functional Description
Technical Manual 4.1 Block Diagram
4 Functional Description
4.1 Block Diagram
The radar system can be extended to up to five MULTIPILOT or RADARPILOT/CHARTRADAR units. If

there are more than two Display Electronics Units or Transceivers in one system it is necessary to use
an Interswitch in a separate housing to switch the radar videos (TVA signals). The "power on" concept
stays the same.
The optional Interswitch is permanently connected to the ship’s mains.
SAM
SAM
Gearbox
Gearbox
Transceiver
Transceiver (Version A/B) with power supply
(Version A/B) with power supply and relay
and relay
1-ph / 3-ph
1-ph / 3-ph Ship's Mains
Ship's Mains
CAN 1, Nav Bus CH1...5 CAN 0 CAN 1, Nav Bus
Ship’s
CAN 0, Radar Bus CAN 0, Radar Bus
Data Ship´s
AIS TVA 1 out TVA 1 out
Data
Gyro TVA 2 out Gyro TVA 2 out
Log TVA in Log TVA
CAN 0 CAN 0
GPS Power On Display Electronics CH1 Interswitch GPS Power On Display Electronics
NMEA GE3062/64/65 ... out ≥ 3 Radars NMEA GE3062/64/65
CH5 (optional) Mains
Mains
with optional with optional
Analog Interface or Analog Interface or
COM-Expander COM-Expander
RGB
RGB RGB
Power- Buffer Power-
On (optional) On
Signal Signal
RGB RGB
Mains
Monitor Monitor
AZ 30xx AZ 30xx
Mains
To Slave-
Monitor
Data (PS/2)
Data (PS/2)
ztr1_005b.eps
Operating Unit
Operating Unit
BD3027
BD3027
Fig. 4-1 Block diagram with wiring concept
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4 Functional Description Gearboxes and Transceivers
4.2 "Power On" Concept Technical Manual
4.2 "Power On" Concept
For the power on concept, see the technical manual of the concerning Display Electronics Unit (radar or
MULTIPILOT). The Transceiver is switched on by means of the 24V ON/OFF signal (two wires, ONN and
ONP). The signal is switched by means of the Display Electronics Unit(s).
NOTE:
If the electronics unit is supplied by a UPS, the mains supply for the Transceiver must be connected inde-
pendently from the UPS.
Only if the capacity of the UPS is sufficient for the supply of the Transceiver and the motor (in 1-ph
systems), the Transceiver can be supplied from it.
4.3 CAN Bus Concept / Termination
See the technical manual of the electronics unit for information about the CAN Bus termination.
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Technical Manual 4.4 Gearbox
4.4 Gearbox
4.4.1 System
To Scanner
Headmarker (S-Band)
Performance
Gear
Monitor
Azimuth
Pulse-
Generator
and
Headmarker
(X-Band)
Performance
Motor Monitor
Start Unit
(S-Band 3-ph
Mains Motor
24 V On/Off
motors only)
Mains
CAN
TVA
Waveguide
Power supply
Connection Board
GR3017G200
Video
Mains IF
Input Unit RF-STC Amplifier
NG3028-
G204 Mains
transformer Transmitter
Control Unit
NG3028G221
Receiver
Limiter
Power Supply Microwave Filter

(X-Band only)
Unit
NG3028G202
Circulator/
T-Junction
Modulator
ztr1_052b.pdf
NG3028G207 Magnetron
Fig. 4-2 Components of the Gearbox GR3040/3041
In version A, all components of Figure 4-2 are mounted inside the Gearbox. In version B, the Transceiver
components are mounted in a separate bulkhead housing. The necessary cabling and the waveguide or
coaxial cable have to be led from the bulkhead housing to the Gearbox.
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4.4 Gearbox Technical Manual
To Waveguide/Scanner
Testoscillator
+5V GND +15V -15V GND
Circulator Limiter RF-Front End IF-Unit
RF-STC
PM TUNE
TUNE IND
PMX T
R F -STC
GND
BWS
TUNE V
Magnetron
+15VDC
+24VDC
-15VDC
+5VDC
IMAG1
IMAG2
ENABLE Video
Modulator Transmitter Control Unit
PULSE
NG3028G207
MAGIND NG3028G221 TVA 1
HeatVoltage
BiasCurrent
CAN 0
SYN A
PMS
HM
High
Voltage
Azimuth Heading Performance

+5VDC Sensor Sensor Monitor
+15VDC
Power Supply -15VDC
NG3028G202 +24VDC
ROT 1
ROT 2
+5V GND +24V GND +24V -15V GND
230VAC 1phase
230VAC / 400VAC 3 phases
Motor Motor Control
24V ON
ztr1_639b.pdf
Transformer Mains Input Unit

NG3028G007 NG3028G204 115/230VAC
Fig. 4-3 Signal diagram Transceiver NG3040/3041
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4.4.2 Description of the Components
4.4.2.1 Scanner
ztr1_027.jpg
Fig. 4-4 S-Band Scanner

ztr1_028.jpg
Fig. 4-5 X-Band Scanner

The Scanners are slotted antennas with horizontal polarization. They are mounted on the Gearbox by
means of a carrier. The dimensions and performance data are stated in Section 8.2.2.
X-Band Scanners
Two versions of the X-Band Scanners exist. The former type of the 5 ft Scanner GR3004G150 has been
replaced by the type GR3020G150.
The former type of the 8 ft Scanner GR3004G160 has been replaced by the type GR3020G160.
Modifications at the Gearboxes have not been made.
S-Band Scanner
Two versions of the S-Band Scanner exists. The GR3009G090 has been replaced by the GR3021G090.
The Scanner GR3021G090 can be used on Gearboxes of the type GR3018Axxx only. Gearboxes of the
type GR3018O000 must be modified by means of a modification kit (see Section 7.6.1).
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4.4.2.2 Motor and Gear
For the X- and S-Band Gearboxes, different motors are available. The 3-phase motors are pole change-
able (Dahlander), which means that they can be switched to the higher or lower rotational speed by the
operator. The double speed capability is to be activated in the System Maintenance Manager menus
by the service technician. The rotation frequency of the 60 Hz motors is about 20% higher. The rotation
frequency of the 60 Hz S-Band Scanners is limited by a modified transmission ratio.
Overview of the available motor versions:
Single-phase:
Supply X-Band S-Band

Supply voltage (V) Phases
frequency (Hz) rpm rpm
230 50 1 23 23
230 60 1 28 28
Three-phase:

frequency (Hz) rpm low rpm high rpm low rpm high
230 50 3 23 46 23 46
230 60 3 28 56 23 46 1)
400 2) 50 3 23 46 23 46
400 60 3 28 56 23 46 1)
1)
Rotation frequency is reduced from 56 rpm to 46 rpm (high speed) and from 28 rpm to 23 rpm (low speed) by modified
gearing.
2)
also for 440 V/60 Hz
S-Band and X-Band motors have different turning directions, but the turning direction of the Scanners is
the same.
4.4.2.2.1 Toothed Belts
For the correct tension of the belts, see Section 7.6.4 on page 122.
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4.4.2.3 Start Unit (S-Band, 3-ph Motor)
To reduce the torque of the starting 3-phase motor of the S-Band Antenna Unit, a start unit is installed,
which switches load resistor(s) into one phase of the supply while the motor starts to turn. The resistor(s)
is/are switched out of the supply by a bypass after 2-3 seconds.
The angled metal sheet
of the start unit can
contain the optional
heating, too. The heating
is supplied by means of
the cable (1) (black/
brown). It is connected to
terminal 4 and F4 of the
connection board.
1
The start unit is
controlled and supplied
via the cable (2) which
must be connected to 2
J8 6/7 of the connection
board. The cable (3)
(black/black) connects 3
the additional load
resistor into one phase. It
must be connected to
ztr1_191.jpg
terminal 9 and 10 of the

connection board.
See Section 10 for Fig. 4-6 Start Unit / Heating (current version) and cabling
further information about
the cabling.
WARNING
For the use of the start unit 2, some prerequisites must be
fulfilled. See Section 6, R e v i s i o n O v e r v i e w for further infor-
mation.
NOTE:
The Start Unit is delivered in two versions, for 230 V and for 400 V mains
supply from 2003-08 on. See the Section 7.9, S p a r e P a r t s for the order
numbers.
4.4.2.4 Antenna Heating (Optional)
The antenna heating consists of two 100 W heating resistors which are switched on or off by a thermo-
stat. The switching temperature is about -10°C or lower. The heating starts to work in cold environmental
conditions even when the Transceiver is switched off, to keep the system always ready to start. See
Section 10 from page 153 on for the connection of the heating. For the X-Band version, the strapping
connectors must be connected dependent on the power supply (1-ph / 3-ph). For the S-Band version, the
cabling of the heating resistors must be performed depending on the power supply (1-ph / 3-ph).
Two versions of the heating for the S-Band Gearbox exist. See Section 4.4.2.3 for further information.
The heating is mounted on an angled metal sheet together with the start unit.
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4.4.2.5 Connection Board (GR3017G200)
In version A (Aloft), one connection board is mounted inside the Gearbox. In version B (bulkhead), an
additional connection board is mounted in the bulkhead housing of the Transceiver Electronics Unit. For
the connection of the boards, see the cable diagrams.
HM = Headmarker J8 Function J2 Function J5 Function J6 Function

PM = Performance Monitor Power-on signal: Performance Monitor: Pulser: Headmarker:
1 24V ON/OFF ONP 1 -15 V, VEE (grey) X-Band 1 +24 V, VP_HMA (red)
2 24V ON/OFF ONN 2 PMS (yellow) 1 GND (black) 2 GND (black)
Antenna speed: 3 GND (black) 2 n.c. 3 Pulse, HMA_IN (brown)
3 GND 4 +24 V, V24 (red) 3 Pulse SYNA (yellow) 4 n.c.
4 ROT1 (Speed 1) 5 n.c. 4 +5 V VCC (red) 5
5 ROT2 (Speed 2) 6 n.c. 5 6
Start Unit: 6
6 Start Unit, S-Band J7 Function
only TCU Rev. 05 1 GND (blue) TVA signal from TCU:
7 GND 2 +24 V VCC (brown) Center TVA
3 n.c. Screen
4 n.c.
5 n.c.
6 Pulse SYNA (black)
Positioning in S-Band Gearbox
J8
J2 J5 J6
1 2 3 4 5 6 7 1 1 1
Q1
1 J3
9/10 J1
1 2 3 4 5 6 7
1 2
F1 F2 F3 F4 1 17
TB3 TB1
ztr1_053.jpg
Power supply: wiring depends on

the ship’s mains. See the cabling J1 Function TB3 Function TB1 Function
documents and page 68.. 1 + 24 V Start Unit 1 24V ON/OFF ONP TVA signal to Indicator:
for TCU Rev. 05 2 24V ON/OFF ONN 1 GND
2 n.c. 3 CAN0_A 2 TVA
Terminals 9 and 10 for the connection of the Start 3 CAN0_A 4 CAN0_B
Unit’s load into phase 1 of an S-Band 3-ph Gearbox. 4 CAN0_B 5 GND J3
See the cabling documents. start unit 2 only. 5 GND 6 V24, +24 V Headmarker input, reed
6 V24, +24 V 7 SYNA contact only (not used)
7 SYNA 8 HMA 1 HM
8 HMA 9 ROT1 (Speed 1) 2 GND
Positioning in X-Band Gearbox 9 ROT1 (Speed 1) 10 ROT2 (Speed 2)
10 ROT2 (Speed 2) 11 VEE, -15 V
11 VEE, -15 V 12 PMS
12 PMS 13 CAN0_A
14 CAN0_B
15 24V ON/OFF ONP
16 24V ON/OFF ONN
17 Start Unit, only
TCU Rev. 05
ztr1_194.jpg
Fig. 4-7 Connection Board Transceiver (example for 3-ph motor), Rev. 01
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4.4.2.5.1 Exchange of Fuses
To change the fuses, open the fuse carrier terminals. No tools are
Fuse
needed to open the terminals.
For the fuses, see page 115.
Depending on the carrier, the fuses are of the type 5x20 or 6x32.
2.
1.
ztr1_163.jpg
Fig. 4-8 Exchange of fuses
4.4.2.5.2 Motor and Contactors
For the wiring of the motors and contactors, see

page 68 and Section 10, C a b l i n g D o c u m e n t s .
K1 K2 K3
ztr1_084.jpg
Contactor and connection unit
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4.4.2.5.3 Shorting Bars for Mains Supply
The Transceiver Electronics Unit (version A = Transceiver up) must be supplied with mains.
The mains supply must be performed depending on the version of the Gearbox by means of a separate
1-ph supply cable or by means of shorting bars at the terminals of the connection board in the Gearbox.
In this case the mains supply is taken from the supply of the motor.
The version B (Transceiver down) systems need no shorting bars or separate supply cables.
A separate cable must be used for Gearboxes with 3-phase motors. The 1-phase mains cable can be
connected at the interconnection box.
For Gearboxes with 1-phase 115 V or 230 V motors, the mains supply can be connected by means of
shorting bars. In case of the 115 V mains supply, all components of the Transceiver must be prepared
for 115 V mains (mains voltage can be selected by means of a switch). Gearboxes with 115 V motors are
not delivered any longer, so that the voltage must be converted to 230 V by means of a transformer.
See the cabling drawings in Section 10 for information in detail.
.
Shorting bars for Separate 1-ph supply for the
Type the supply of the supply of the Transceiver
Transceiver 1) necessary
S-Band Version A
1-ph 230V X - (X 2))
3-ph 230V 3) - X
3-ph 400V 3) - X
S-Band Version B
1-ph 230V - -
3-ph 230V 3) - -
3-ph 400V 3) - -
X-Band Version A
1-ph 230V X - (X 2))
3-ph 230V - X
3-ph 400V - X
X-Band Version B
1-ph 230V - -
3-ph 230V - -
3-ph 400V - -
1) Shorting bar between the terminals 1 and 5 and between the terminals 2 and 6 of the Connection
Board Transceiver
2) )Alternatively possible
3)
Start unit necessary
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4.4.2.6 X-Band Azimuth Pulse Generator and Combined Azimuth/Headmarker Pulse Generator
Former Version (HEDS-5605)

This azimuth pulser has been used until March
2005. If it is defective, it must be replaced by a
different type as described in Section 7.6.10 on
page 127. The azimuth pulse generator for the
X-Band Antenna Unit is a two-channel optical
incremental encoder which is mounted directly Pin 1
on the motor’s axle. For the radar only one
channel is used. The pulser generates 1920
pulses per revolution of the Scanner. The
correct setting has to be made in the Mainte-
nance Manager menus. The pulse generator is
connected to J5 of the connection board.
Terminal
Function Colour (connection board)
ztr1_055.jpg
GND black J5 / 1
Pulse yellow J5 / 3
Fig. 4-9 Azimuth Pulse Generator HEDS-5605, X-Band
+5 V red J5 / 4
Spare Part Version GR3017G027 for HEDS-5605

A spare part kit GR3017G027 is available to replace the pulser HEDS-5605. A Technote is contained in
the spare part kit which describes the exchange. The pulser generates 540 pulses per revolution of the
Scanner. The correct settings have to be made in the Maintenance Manager menus. The spare part kit
contains a new pulser OPB480T11 and a slotted wheel which are mounted near the same place at the
intermediate shaft as the HEDS-5606.
Combined Azimuth/Headmarker Pulse Generator

From gearboxes with the Rev. 05 or higher and
gearboxes GR3040, a new type of pulser is used,
which combines the headmarker and the azimuth
pulse generator. The pulser type OPB480T11
generates 72 pulses per revolution of the Scanner.
The headmarker is of the type OPB916BOC. The
correct settings have to be made in the Mainte-
nance Manager menus. Both pulsers are photoelec-
tric barriers, which are mounted beside a slotted
wheel. The slotted wheel is fixed below the hollow
shaft and not below the intermediate shaft.
ztr1_648.jpg
Fig. 4-10 Combined Azimuth/Headmarker Pulse Gener-

ator, X-Band
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4.4.2.7 S-Band Azimuth Pulse Generator
The pulse generator of the S-Band Antenna Unit is mounted near a chopper wheel. It generates 415
pulses per revolution of the Scanner.
The pulse generator can be connected directly to J5 of the connection board.
Terminal
Function Colour (connection board)
+ 24 V Brown J5 / 2
GND Blue J5 / 1
Pulse Black J5 / 6
17 teeth
1.0 mm
Pulser: order No. 300004129,

ztr1_182.jpg
manufacturer No. 9962-4200
Chopper wheel: 17 teeth
Fig. 4-11 Distance between chopper wheel and pulser end face
For the pulser No.: 5240513 (9962-1400)

The distance between the pulser’s end face and the chopper wheel should be about 0.5 mm. The
chopper wheel must have 34 teeth and the pulse rate must be set to 830.
For the pulser No.: 300004129 (9962-4200)
The distance between the pulser’s end face and the chopper wheel should be about 1 mm. The
chopper wheel must have 17 teeth and the pulse rate must be set to 415.
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ztr1_181.jpg
ztr1_114.jpg
Fig. 4-12 S-Band pulser with and without shield cover
4.4.2.8 Headmarker
The headmarker consists of a hall sensor which is

fixed at the gear shaft inside the Gearbox. The
headmarker is not mechanically adjustable. It has to
be adjusted by means of the service menus. The
range for the software adjustment is ±180°.
.
Function Colour Connector Pin
+ 24 V, VP_HMA Red 1
GND Black 2
Pulse, HMA_IN Brown 3
ztr1_0735jpg
From March 2005 on, for X-Band radars a new type

of pulser is used, which combines the headmarker
and the azimuth pulse generator. See Section
Fig. 4-13 Headmarker
4.4.2.6 on page 69 for further information.
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4.4.2.9 Performance Monitor
The performance monitor measures the strength of the transmitted signal and the sensitivity of the
receiver. The test oscillator for the performance monitor is mounted on the waveguide next to the
receiver.
ztr1_050.jpg
ztr1_098.jpg
Fig. 4-14 Performance Monitor window in X-Band Gearbox, Test Oscillator
Measurement of Signal Strength

On the outer surface of the Gearbox there is a microwave detector diode which directly receives the
transmitted signal of the Scanner. The amplitude of the output of this diode is proportional to the signal
strength and the Scanner position. The signal is called PMA and is visible on the screen as an illuminated
sector in the direction of the diode with a radius of 16 NM.
Measurement of Receiver Sensitivity

For the measurement of the receiver sensitivity (PMV) a second test signal which lies outside the display
space is used. Depending on the amplitude and the noise factor the signal is processed and displayed
as an illuminated disc. The diameter of the disc depends on the receiver sensitivity.
Adjustment
The adjustments and the PPI display of the performance monitor are described in the technical manual
of the electronics unit.
TRI TRI
~1.2 ms
75-200 µs 200 µs
PMI setting PMV & PMA

ztr1_074.eps
measurement
PRF
Fig. 4-15 Performance monitor, time diagram
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Technical Manual 4.5 Transceiver
4.5 Transceiver
4.5.1 Modulator NG3028G203 / NG3028G206
TP4 TP8
1
1
TP6
1
TP7
TP1
1
32 1
J1c
J1a
ztr1_623.jpg
TP2
Fig. 4-16 Modulator NG3028G206 Rev. 04 (NG3028G203 Rev. 02 with different components)
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4.5 Transceiver Technical Manual
Connectors / Jumpers / Test Pins

TP1 Function
G203 Rev. 02 and G206 Rev. 04
G203: Not available
1...4 G206: Magnetron selection, see Section 4.5.1.2 on page 75.
G207: Magnetron selection, see Section 4.5.1.2 on page 75
TP2 Function
1
Jumper on 1 and 2 = 25/30 kW Modulator NG3028G206
2 Jumper on 2 and 3 = 12.5 kW Modulator NG3028G203
3
TP4 Function
1 Jumper on 1/2 = power supply MIC4451 - default, do not remove
2
TP6 Function
1 Jumper, HEATER_P, for manufacturer’s use, do not remove
2
3 Jumper, bias current, for manufacturer’s use, do not remove
4
TP7 Function
1 IMAGNETRON
TP8 Function
1 HEATER_N
2 HEATER_P
3 -
4 -
5 -
4.5.1.1 Bias Adjustment
NG3028G203 Rev. 02 and NG3028G206 Rev. 04

The bias is preadjusted and cannot be modified.
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4.5.1.2 Magnetron Selection for NG3028G203/NG3028G206
For NG3028G206 the adjustment for the magnetron heating voltage is performed by the selection of the
magnetron type. The selection/setting has to be performed by means of jumpers. The bias is preadjusted
and cannot be modified.
NG3028G203: No further adjustments or settings are necessary. TP1 is not available.
NG3028G206:
TP1 Type of Magnetron Jumper
NJRC M1475A Jumper on 1/2 and on 3/4
EEV MG5459 Jumper on 3/4, no jumper on 1/2
NJRC 1302L, EEV MG5223 Jumper on 1/2, no jumper on 3/4
4.5.1.3 Functional Description NG3028G203/NG3028G206
The Modulator transforms the TTL pulses from the TCU into power pulses to trigger the magnetron, which
generates the RF transmission pulses with the adjusted length, power and frequency.
The Modulator pcb is delivered in two versions for the 12.5 kW Transceiver (NG3028G203) and for the
25/30 kW Transceiver (NG3028G206). The versions differ only in a few components.
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4.5.2 Modulator NG3028G207
TP11
1
TP 1
1
32
J1c
J1a
Fig. 4-17 Modulator NG3028G207 Rev. 00 for advanced performance standards
The new modulator NG3028G207 - Rev. 00 - 390004915 has been designed to meet the requirements
of the advanced performance standards. Major changes on the hardware:
Some electronic parts have been exchanged. An additional function for the treatment of short pulses has
been added. The connector J1a/c is the same as for the former versions, all TP´s except for TP1 have
been removed. Adjustment is done by software now, please refer to the operating instructions.
4.5.2.1 Magnetron Selection for NG3028G207
For NG3028G207 the adjustment for the magnetron heating voltage is performed by the selection of the
magnetron type. The selection/setting has to be performed by means of jumpers. The bias is preadjusted
and cannot be modified.
NG3028G207:
Magnetron model Transceiver type TP 1 / 1-2 TP 1 / 3-4 TP 11 / 1-2
MSF1425A / MG5245 12,5 kW X-Bd OPEN CLOSED OPEN
M1475A 25 kW X-Bd CLOSED CLOSED CLOSED
MG5459 25 kW X-Bd OPEN CLOSED CLOSED
M1302L / MG5223 30 kW S-Bd CLOSED OPEN CLOSED
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4.5.3 Pulse Length and PRF (all types of modulators)
The pulse repetition rates in relation to the range and the pulse length are shown in the following table:
Scanner rotation frequency 23/28 rpm

1)
Range (NM) 0.25 0.50 0.75 1.5 3 6 12 24 48 96
Short pulse 1.00 2)
0.08 0.15 0.30 0.50 (
Pulse length (µs) 3)
0.90
PRF (Hz) 2000 1000 500
Long pulse 1.00 2)
0.15 0.30 0.50 3)
Pulse length (µs) 0.90
PRF (Hz) 1000 500
1) All values of the 0.25 NM range are also valid for the 250 m/500 m ranges
2)
12.5 kW X-Band Transceiver
3)
25 kW X-Band and 30 kW S-Band Transceiver
Scanner rotation frequency 46/56 rpm

1)
Range (NM) 0.25 0.50 0.75 1.5 3 6 12 24 48 96
Short pulse 0.08 0.15 0.30 0.50
Pulse length (µs)
PRF (Hz) 2000 1000
Long pulse 0.15 0.30 0.50
Pulse length (µs)
PRF (Hz) 1000
1) All values of the 0.25 NM range are also valid for the 250 m / 500 m ranges
Depending on the range and the pulse length the magnetron current is set for the different pulse lengths
by a D/A converter.
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4.5.4 Microwave Unit
The microwave unit consists of the magnetron, the circulator, the limiter and the receiver. These compo-
nents are different for the X- and S-Band versions of the Transceiver and for the different versions
(NG3028/3029 and NG3040/3041) of the transceiver itself. See Section 8.2 for technical data.
4.5.4.1 X-Band Microwave Unit of NG3028
TCU Magnetron (back) Microwave filter IF amplifier

ztr1_029.jpg
ztr1_065.jpg
Power supply Circulator Limiter Receiver
Fig. 4-18 X-Band Microwave Unit of NG3028
The microwave unit consists of the magnetron, the controllable limiter with circulator, and the microwave
receiver.
The magnetrons are pulse magnetrons which, as the transmitter output stage, release the pulse power
to the Scanner. They work with a frequency of 9375 MHz, with a peak output power of 12.5/25 kW.
At the instant of transmission the diode limiter, together with the circulator, protects the receiver against
the transmission pulse. The microwave receiver unit receives the echo pulses and transforms them into
the IF frequency of 60 MHz.
Magnetron selection
See Section 4.5.1.2 on page 75 for magnetron selection and the adjustment of the heating voltage.
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4.5.4.2 X-Band Microwave Unit of NG3040
TCU Magnetron (back) Microwave filter

ztr1_686.jpg
Power supply Circulator Limiter HF-Unit
Fig. 4-19 X-Band Microwave Unit of NG3040
The microwave unit consists of the magnetron, the controllable limiter with circulator, and the HF-Unit.
The magnetrons are pulse magnetrons which, as the transmitter output stage, release the pulse power
to the Scanner. They work with a frequency of 9375 MHz, with a peak output power of 12.5/25 kW.
At the instant of transmission the diode limiter, together with the circulator, protects the receiver against
the transmission pulse. The HF-Unit receives the echo pulses and transforms them into the IF frequency
of 60 MHz.
Magnetron selection
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4.5.4.3 S-Band Microwave Unit of NG3029
Mains Input unit To/from Scanner Receiver Limiter Modulator

ztr1_029.jpg
IF amplifier T-junction PM test oscillator Magnetron Power supply
Fig. 4-20 S-Band Microwave Unitof NG3029
The microwave unit consists of the magnetron, the T-junction, the controllable S-Band limiter and the
microwave receiver.
The magnetrons are fixed band pulse magnetrons which, as the transmitter output stage, release the
pulse power to the Scanner. They work with a frequency of 3050 MHz and with a peak output power of
30 kW.
Different versions of the limiter are in use. See the label on the limiter for the type.
At the instant of transmission, the controllable S-Band limiter protects the microwave receiver against the
transmission pulse.
The microwave receiver unit receives the echo pulses and transforms them into the IF frequency of
60 MHz.
Magnetron selection
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4.5.4.4 S-Band Microwave Unit of NG3041
Mains Input unit To/from Scanner Limiter Modulator

ztr1_687.jpg
HF-Unit T-junction PM test oscillator Magnetron Power supply
Fig. 4-21 S-Band Microwave Unit of NG3041
The microwave unit consists of the magnetron, the T-junction, the controllable S-Band limiter and the HF-
Unit.
The magnetrons are fixed band pulse magnetrons which, as the transmitter output stage, release the
pulse power to the Scanner. They work with a frequency of 3050 MHz and with a peak output power of
30 kW.
At the instant of transmission, the controllable S-Band limiter protects the microwave receiver against the
transmission pulse.
The HF-Unit receives the echo pulses and transforms them into the IF frequency of 60 MHz.
Magnetron selection
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4.5.5 IF Amplifier NG3028G022 and NG3028G080 for NG3028/3029
The IF amplifier combines a logarithmic and an IF preamplifier. The

IF Input
IF amplifier prepares the incoming receiver signal for the TCU,
where it is processed to form the combined video signal (TVA).
The video amplitude can be adjusted with R49 (NG3028G022) or
R36 (NG3028G080) to -2 V at 75  load (set radar to long pulse
without SEA (STC)). The signal can be measured at TB43 1/3 of
the TCU.
The adjustment must be performed while the amplifier is mounted.
It has been performed ex works for new Transceivers units. It IF STC
should be checked after exchanging the amplifier.
Further adjustments are not necessary. In the case of a defect, the
IF Amplifier must be exchanged. It is possible to replace the older
type NG3028G022 by the newer type NG3028G080. A sparepart
kit is available for this purpose.
R49
For the replacement of an IF Amplifier, see Section 7.6.15 for
further information.
Power Video
NG3028G022 supply
ztr1_058.jpg
If the cable length of the TVA cable between the Transceiver and
the Display Electronics Unit is longer than 150 m, it could be
possible that the video amplitude cannot be adjusted to -2 V (meas-
ured at the Electronics Unit RSC TP11/1). In this case, the potenti- Fig. 4-22 IF amplifier NG3028G022
ometer R49 on the pcb NG3013G212 must be exchanged. If a
500  potentiometer is installed, it must be replaced by a 2 k potentiometer (order No. 5102258).
NG3028G080
IF Input
For the adjustment of the video
amplitude, the housing must be
opened. It is necessary to
remove the amplifier to gain
access to the screws of the
cover.
R36
Power
supply
IF STC
ztr1_626.jpg
ztr1_625.jpg
Video
Fig. 4-23 IF amplifier NG3028G080
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4.5.6 HF Unit NG3028G205 for NG3040/3041
The HF Unit is a completely new designed component of the radar transceiver. (The picture shows the
X-band version, IF-amplifier and microwave receiver). It is always part of the appropriate HF-unit and can
not be delivered as single spare part.
X-Band: NG3040G009, Material No: 390005481,
S-Band: NG3041G005, Material No: 390005456.
J41
J42
J43
J41 J42 J43
Connectors:
J41 Ribbon cable for the connection to the TCU
J42 Coaxial cable for radar video
J43 Coaxial cable for signals to the limiter
NOTE:
This unit can only be operated together with a TCU NG3028G221 (390005129), revision 00, a modulator
NG3028G207 (390004615), revision 00, a power supply NG3028G202 (2859950) of at least revision
07and software version of at least 5.0.0. !
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4.5.7 Transmitter Control Unit (TCU) NG3028G201/G221
DIP Switch S1/1...3, Transceiver Number Switch No. TP53 Function

on=closed=0; off=open=1 3 2 1 1 Jumper on 1/2 =
termination of CAN0
Sets Transceiver No. to 1 Off Off Off (radar bus), 120 
2 No jumper on 1/2 =
Sets Transceiver No. to 2 Off Off On CAN0 not terminated
Sets Transceiver No. to 3 Off On Off at this pcb
Sets Transceiver No. to 4 Off On On

Sets Transceiver No. to 5 On Off Off
DIP Switch S1/4....8 Function

Off On
1
4 Internal trigger (default) External trigger-mode on
5 Default Not permissible, set to Off
6 25/30 kW Transceiver 12.5 kW Transceiver
7 S-Band Transceiver X-Band Transceiver ON
8 Normal operation (default) Service Mode on
E3 E6 E1 TP71 TB70
S1 DS9... ...DS1
10 1
TB43
1 1
1
S2
E2 1 ON ON
TP92
1 TP52
TP42
TP51
TP61 1
1
TP41
TP54 1
5 1
1
1
1
TP31 1
TP32
32 1 1 4 1
J2c TP12
1
J2a 5 8
ztr1_.192jpg
TP62 TP53 J1 TP13 R182 E4 E5
Fig. 4-24 Transmitter control unit (TCU) NG3028G201, Rev. 05
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E3 E1 TP71 TB70 DS9... ...DS1

E6 J3
TB43
10 1 1 1
1
S2
E2 1
TP92 ON ON
1 TP52
TP42
10 1 TP51
TP61 1
1
TP54 1 TP41
5 1 1
1
1
TP31
TP32
32 1 4 TP12
J2c
1
5 8 R182
J1
TP53 E4 E5
TP62
Fig. 4-25 Transmitter control unit (TCU) NG3028G221, Rev. 00

Coaxial Function
connectors
E1 VIDEO_IN
E2 IF_STC
E3 TVA1
E4 EXT_TRIG_IN
E5 PRETRIG_OUT
E6 RF_STC
J1 Function
1 AGND
2 GND
3 GND
4 GND
5 VIDOUT
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6 HMOUT
7 SYNOUT
8 TRIGOUT
J3 1) Function
3 TUNEVIN
4 VIDOK1
5 VDD
6 AGND
7 VEE
12 ZF SEL
14 TR_ZF
15 BWSN
16 TUNE_IND1
18 AGND
20 RFSTC_N
1)
J3 is available on NG3028G221 only !
TB43 Function
1, 2 TVA2
3, 4 AGND
TB70 Function
1 GND, serial interface (option)
2 DVTxD, serial interface (option)
3 DVRxD, serial interface (option)
4 n.c.
5 GND, debug interface RS232, or boot interface for jumper on 9/10
6 VTxD, debug interface RS232, or boot interface for jumper on 9/10
7 VRxD, debug interface RS232, or boot interface for jumper on 9/10
8 n.c.
9 BOOT, debug interface RS232, or boot interface for jumper on 9/10
10 GND, debug interface RS232, or boot interface for jumper on 9/10
TP11, TP41, TP51, TP52 are for manufacturer´s use only. It is not permissible to connect cables or
jumpers to one of these contacts.
TP12 Function
1 RESET IN
2 GND
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TP13 Function
1/2 Jumper on 1/2 = external trigger is negative, no jumper on 1/2 = external trigger is positive
TP31 Function
1 IMAG1 Jumper on 1/2 is default setting, do not remove
Pin 2 = SYN_A
2 AGND
3 - Jumper on 2/3 for manufacturer’s use only
Jumper on 4/5 for manufacturer’s use only
4 -
5 -
TP32 Function
Jumper on 1/2 is default setting, do not remove
1/2 Pin 2 = HMA
3 Jumper on 2/3 for manufacturer’s use only
Jumper on 4/5 for manufacturer’s use only
4
5
6 -
7 -
8 -
TP42 Function
1 IMAG1
2 IMAG2
TP54 Function
1 Jumper on 1/2 = 28 VB
No jumper on 1/2 = 24 VB, default setting
2 Pin 2 = TUNVIN
3 Not connected
TP61 Function
1 MAGIND B
2 AGND
TP62 Function
1 TUNEV
2 PM_TUNE
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TP71 Function
1 PMA
2 ASTC
3 TUNEI
4 PMV
5
6 VIDOK
7 HEV
8 BIV
TP92 Function
1 IF-STC
2 RF_STC
DIP Switches of NG3028G201/221
DIP Switch 2 1) Function

Switch No. OFF ON
1 No function No function
Enables the indication of heating voltage and BIAS
2 Not permissable, set to ON current on the indicator
Must be toggled to the other position Must be toggled to the other position after every
3 after every exchange of the magnetron or exchange of the magnetron or modulator.
modulator.
IF amplifier NG3028G080 or NG3032G205
4 Not permissible, set to ON (default)
5 Default Not permissible, set to OFF
TCU operates together with old modu- TCU operates together with new modulator
6 lator NG3028G203/G206 NG3028G207
7 Azimuth simulation off (default) Azimuth simulation on
8 Magnetron current control off Magnetron current control on (default)
1)
on=closed=0; off=open=1
LEDs
DS Colour Function
Red Error - On if at least one error is present
DS1 External trigger - On if an external trigger is present. The brightness depends on
Green the frequency of the external trigger
Red Head marker - Toggling with each head marker pulse
DS2
Green Azimuth - On if antenna pulses are detected
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Stand-by heating - On in stand-by mode, flashing while the magnetron is heating

Red
DS3 up
Green On if Transceiver is in normal operation mode
Red CAN TXD - Alight while transmitting CAN telegrams
DS4
Green CAN RXD - Alight while receiving CAN telegrams
Red Self-check - System is processing a self-check
DS5
Green Not used
Red Not used
DS6
Green Flashing at 1 Hz (program running)
Red PRF control - PRF processor is working
DS7
Green RSTOUT - C167 controller initialization finished
Red Not used
DS8
Green Not used
Red Not used
DS9
Green Not used
Potentiometers
Function
R182 External trigger (amplitude)
4.5.7.1 Service Switch of the TCU
If the service mode is activated by means of the DIP switch S1/8, the following functions are available:
- If the Scanner stops turning, the Transceiver is not switched off.
- If the magnetron current exceeds or falls short of its limits, the Transceiver is not switched off.
- If a communication time-out occurs in the communication with the master indicator, the Transceiver
is not switched off.
If the service mode of the RDC (S1/8) in the Display Electronics Unit is activated, the service mode func-
tions of the TCU are available also. If the service mode of the TCU is activated, the service mode func-
tions of the RDC are not available, so that it is advisable to activate the service mode by means of the
switch S1/8 of the RDC. See also the safety warnings on there!
The maintenance menus can be entered and used without the use of the service switch. The service
mode offers the additional functionalities described above, especially for the setting-to-work phase.
NOTE:
The service mode must not be activated during normal operation! If the service mode is activated, a
frozen radar video might be displayed at the Indicator if the Transceiver is switched off!
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4.5.7.2 Hardware Description of the TCU
The operating system and the parameters are loaded from the main processor of the Display Electronics
Unit into an EEPROM of the TCU. The EEPROM stores these parameters for the radar system.
The TCU coordinates and controls all transmit and receive functions. It coordinates the running of the
individual operating modes and generates the required timing signals. The communication with external
units (e.g. the Display Electronics Unit) is done via the CAN Bus.
The TCU also generates the combined video signal (TVA) from the receiver’s output and the additional
trigger and azimuth signals.
In service operation status, special functions such as parameter adjustment and telediagnostic service
can be operated.
The TCU supports the standard pulse repetition frequencies of 2000/1000 and 500 Hz.
The TCU generates the trigger signal (TRI) for the start of the transmission.
The Transceiver reports its type (X-Band, S-Band) via CAN Bus to the connected Display Electronics
Units.
4.5.7.3 Software Description of the TCU
The TCU software has the following functions:

- The Transceiver is operated by the Display Electronics Unit via the CAN Bus. The TCU provides the
CAN Bus interface for the Transceiver.
- Debug function via an additional interface
- Storage of all transceiver parameters in an EEPROM
- Storage of all system parameters in an EEPROM
The TCU contains the control software for the Transceiver. The orders are sent via CAN Bus from the
Display Electronics Unit to the TCU. The software starts to run itself when "power-on" of the Transceiver
occurs. If the system is switched over to the service mode, a remote diagnosis and adjustment routines
are available. The service parameters determined are stored in a non-volatile memory.
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4.5.8 Power Supply Unit NG3028G202
J8 J5 J4 J6
1 4 1 4
5 8 5 8
1
J2c
J2a
32 1
2 32
J1a
J1c
1
1
1
1
F1
2 14
1 1 13
J3 TP3 TP2 J9 TP1 J7
Fig. 4-26 Power supply
WARNING
For the use of this pcb with the new transceivers NG3040/
3041 this unit MUST be of a revision  07 !

Connectors Function and most important contacts
To Modulator
J1 A4 = Heater voltage; C4 = Bias current; A6 = J2/C5; A8, C8, C14, C22, A24, C24 = GND; A18 =
IMAG1; C18 = MAGIND; A20 = ENOUT; A22 = PULSE; C6 = IMAG2;
J2 To TCU
To transformer
J3 1 = 0 V; 2 = 490 V, 3 = 710 V
To RF front-end
J4 1 = 15 V test voltage; 2 = TUNEV0; 3 = GND; 4 = 5 V
To test-oscillator
J5 1 = PMX_T; 2 = PM_TUNE; 3 = PMX_B; 4 = PM_BIAS; 8 = GND;
To transformer
J6 1 = 13 V A; 2 = GND1; 3 = 13 V B; 4 = 12 V A; 5 = 12 V B; 6 = 17 V A; 7 = GND1; 8 = 17 V B;
9 = 24 V A; 10 = 24 V B
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To IF/log. amplifier
J7 1 = TUNE_IND; 2, 4, 6, 10 = GND; 3 = +15 V; 5 = -15 V; 8 = BWS2; 9 = BWS
To connection board
J8 1 = Start; 3 = CAN0 A, 4 = CAN0 B; 5 = GND; 6 = 24 V; 7 = SYN_A; 8 = HMA; 9 = ROT1; 10 =
ROT2; 11 = -15 V; 12 = PMS
To HV supply switch (interlock)
J9 1 = 2, switch between 1 and 3
TP1 Function
1 Jumper 1/2 for +5 V, for test purposes
2
4
5 Jumper 5/6 for -15 V, for test purposes
6
8
TP2 Function
1 Jumper on 1/2 = 12.5 kW Modulator
2
TP3 Function
1 Jumper on 1/2 = 25/30 kW Modulator
2
Fuse
F1 For the fuse, see page 115.
The power supply unit generates all voltages for the Transceiver Electronics Unit and all connected units
(performance monitor, azimuth pulse Generator, headmarker, IF amplifier).
All low voltages are continuously measured. The power supply unit generates a status signal depending
on the result of the measurements. This signal is controlled by the processor, which generates an alarm
if an error occurs.
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4.5.9 Mains Input Unit NG3028G204
The mains input unit is connected to a transformer.

The transformer is switched on by a "power on"
signal (24V ON/OFF) from the Display Electronics
Unit. The "power on" signal is connected to a relay,
which switches the transformer on or off. The AC
outputs of the transformer are connected to the
power supply and the Modulator.
The mains input unit consists of the following compo-
nents:
- Mains input
- Fuses
- Mains filter
- Power-on relay TB5
- Transformer TB4
TB3
- Terminals for the cabling of mains filter, fuses,
relay
Fuses TB2
For the fuses, see page 115. TB1
Voltage Selector Switch

The voltage selector switch must be set corre- 115 V
sponding to the ship’s mains (supply) voltage. 230 V
TB10
TB6
TB7
TB8
TB9
Terminals
The wires of terminals TB6...TB10 must not be
changed! The transformer’s primary is connected via
these wires. The wires have to be disconnected only
ztr1_030.jpg
for the exchange of the pcb or the transformer.
Fig. 4-27 Mains Input Unit
Terminal Function Terminal Function

TB1 24V ON/OFF ONP TB6 Black
TB2 24V ON/OFF ONN TB7 Grey
TB3 L1 TB8 Orange
TB4 PE TB9 Violet
TB5 N TB10 Green/yellow
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Gearboxes and Transceivers 5 Setting-To-Work/Configuration
Technical Manual 5.1 Setting-to-Work Guide
5 Setting-To-Work/Configuration
5.1 Setting-to-Work Guide
The setting-to-work routine of a complete radar system is described in the technical manual of the Display
Electronics Unit.
The Transceiver and the Gearbox must be mounted and connected as stated in sections 3 (I n s t a l l a t i o n
R e c o m m e n d a t i o n s ), 10 (C a b l i n g D o c u m e n t s ) and 11 (O u t l i n e D r a w i n g s ).
Most of the adjustment and configuration of the Transceiver must be performed at the display electronics
Unit. See the corresponding technical manual for further information.
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5 Setting-To-Work/Configuration Gearboxes and Transceivers
5.2 Upgrade Kits Technical Manual
5.2 Upgrade Kits
Switch off the power supply to the system before starting the installation process!
5.2.1 Gearbox Heating Kits
The heating kits can be used for two purposes:

- Retrofit of a heating.
- Exchange of older versions of the heating.
Usually it is not necessary to exchange older versions of the heating, because it is working in perfect
order. Under certain circumstances it makes sense to have the new version of the heating, because the
position of the thermal switch is different.
5.2.2 X-Band Gearbox Heating Kits GR3017G060 and GR3017G070
The following kits are available:

- Retrofit of a heating: GR3017G060, order No. 390000356.
- Exchange/upgrade of older versions of the heating: GR3017G070, order No. 390000358.
Retrofit:
1. Replace the grounding bolt. The new grounding bolt is contained in the heating
kit. The thermal switch is mounted with the new grounding bolt, see Figure 5-1.
2. Mount the 4 distance bolts instead of the two recessed-head screws with which
the waveguide is fixed.
NOTE!
The two recessed-head screws must not be untightended at the same time,
because the waveguide could come maladjusted.
Some Gearboxes still have a distance bolt instead of the screws. In this case, an
additional bolt must be mounted on the existing bolts. ztr1_646.gif
3. Mount the heating plate on the distance bolts.

4. Cable connection (see also Section 10, C a b l i n g D o c u m e n t s ):
- Connect the brown wire to the thermal switch and the terminal 4 of the Heating
Connection Board Transceiver.
- Connect one of the blue wires to the thermal switch and to the terminal 4 of the heating termi-
nals.
- Connect the other blue wire to the fuse F4 and to the terminal 1 of the heating terminals.
5. Connect the shorting bars at the terminals of the heating corresponding to the mains supply voltage
(see Section 10, C a b l i n g D o c u m e n t s ).
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Gearboxes and Transceivers 5 Setting-To-Work/Configuration
Technical Manual 5.2 Upgrade Kits
ztr1_645.gif
2 x 2 distance bolts
Bottom view
ztr1_647.gif
ztr1_643.gif
Thermal switch
Thermal switch
ztr1_644.gif
Grounding bolt
Top view
Fig. 5-1 Heating retrofit for the X-Band Gearbox
Exchange
If a heating is installed, the grounding bolt and the thermal switch must be exchanged and the wires must
be connected as described above (retrofit). The heating itself must not be modified.
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5 Setting-To-Work/Configuration Gearboxes and Transceivers
5.2 Upgrade Kits Technical Manual
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Gearboxes and Transceivers 6 Revision Overview
Technical Manual 6.1 Prerequisites for the Use in a RADAR 1100 Series System
6 Revision Overview
6.1 Prerequisites for the Use in a RADAR 1100 Series System
6.1.1 Transceivers NG3028/NG3029
If the Transceiver NG3028/NG3029 is used in a RADAR1100 series system, specific revisions (or newer
revisions than these) of some components must be used. When older revisions are used, the correct
function is not ensured.
Also separate technical manuals are available:
For Transceivers/Gearboxes for the RADAR 1000 series:
- Technical manual ED3038G442.
This manual contains the description of all revisions and versions of the Transceivers/Gearboxes.
For Transceivers/Gearboxes for the RADAR 1100 series:
- Technical manual ED3051G442.
This manual contains only the revisions/versions of the Transceivers and Gearboxes which are valid for
the RADAR 1100 series.
See the following table for the components and their revisions, which are required for the use in a RADAR
1100 series system:
Component Revision Remark
X-Band
Power supply unit NG3028G202 Rev. 05
Modulator NG3028G203 (12.5 kW) Rev. 03
Modulator NG3028G206 (25 kW/30 kW) Rev. 05
Microwave Filter - must be installed if not existing
IF-amplifier NG3028G080 all NG3038G022 also permissible
with software version M/01.10.04
Transmitter control unit NG3028G201 Rev. 06 or newer; update by means of indi-
cator software possible
S-Band
Power supply unit NG3028G202 Rev. 05
Modulator NG3028G206 (25 kW/30 kW) Rev. 05
IF-amplifier NG3028G080 all NG3038G022 also permissible
with software version N/07.04.05 or
Transmitter control unit NG3028G201 Rev. 06 newer; update by means of indi-
cator software possible
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6 Revision Overview Gearboxes and Transceivers
6.1 Prerequisites for the Use in a RADAR 1100 Series System Technical Manual
6.1.2 Transceivers NG3040/NG3041
If the Transceiver NG3040/NG3041 is used in a RADAR1100 series system in order to fulfil the advanced
performance standards, the software version of 5.0.0. or higher must be installed and the hardware must
be of the latest version as described in Section 6.2.1 on page 102.
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Gearboxes and Transceivers 6 Revision Overview
Technical Manual 6.2 List of Revisions
6.2 List of Revisions
This table shows the differences in the functionality and the necessary prerequisites for the use of the
different revisions of hardware or software components. For a description in detail, see the corresponding
sections in the Technical Manual. The following table is only an overview. If an item has to be exchanged,
the same revision or a newer one must be used.
Component Extended / different

(Hardware / Soft- Prerequisites Remarks
functionalities
ware)
Gearbox Modified for the new Scanner GR3021G090 Former version: GR3018O000
GR3018Axxx Scanner Current version: GR3018Axxx
GR3021G090 The Gearbox has been modi-
fied for the use of the new
Scanner GR3021G090 and it
can be used with this Scanner
only. The rotary joint is inside
the Gearbox (Transceiver up)
or below the Gearbox (rotary
joint). Modification kits for the
former version of the Gearbox
are available (see Section
7.6.1).
Scanner Gearbox GR3018Axxx or Replaces the Scanner
GR3021G090 Gearbox GR3018O000 with modi- GR3009G090. It can be used
fication kit. only with a Gearbox of the
type GR3018Axxx The rotary
joint is located inside the
Gearbox or below the
Gearbox.
Modification kits for the former
version of the Gearbox are
available (see Section 7.6.1).
Pulse Generators Spare part kit Must be used in case of a
GR3017G027 defective Pulse Generator
HEDS-5605. The Headmarker
must be replaced also
(included in the spare part kit)
Gearbox GR3040/ Contains the new Software version of 5.0.0. or
GR3041 transceiver NG3040/ higher must be installed and the
NG3041 for new hardware must be of the latest
performance stand- version as described in Section
ards 6.2.1 on page 102.
Transceiver Designed to fulfil the Software version of 5.0.0. or
NG3040/NG3041 new performance higher must be installed and the
standards, contains hardware must be of the latest
new TCU and HF- version as described in Section
unit. 6.2.1 on page 102.
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6 Revision Overview Gearboxes and Transceivers
6.2 List of Revisions Technical Manual
6.2.1 Hardware for New Performance Standards
In order to fulfil the requirements of the "New Performance Standards" 1) which are relevant since July 1st
2008, hardware and software of the system have to be upgraded. The following hardware compo-
nents must be used together in a system:
Part New Part No New Material No

Gear Box S-Band GR3041
Gear-Box X-Band GR3040
Modulator NG3028G207 390004915
TCU NG3028G221 390005129
X-Band HF-unit NG3040 G009 390005481
(contains IF-Amplifier)
S-Band HF-unit NG3041 G005 390005456
(contains IF-Amplifier)
NG3028G202
Power-Supply 2859950
Rev  07
Transceiver X-Band 12,5 kW NG3040G010 390005429
Transceiver X-Band 25 kW NG3040G015 390005430
Transceiver S-Band NG3041G010 390005451
Further on, a software version of 5.0.0. or higher is required on the RADAR1100/MULTIPILOT1100 elec-
tronics unit.
1)
If a system is not intended to fulfil the requirements of the new performance standards, no hardware must be changed. The software can
be upgraded anyway.
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Gearboxes and Transceivers 7 Repair/Maintenance
Technical Manual 7.1 Service Kit NG3028G073 / NG3029G073 for Version A Transceivers
7 Repair/Maintenance
GENERAL:
The jumper settings and switch settings on a replacement pcb must be

the same as on the defective pcb. The wire connections must be made
in exactly the same way. Exceptions are explained in this manual.
7.1 Service Kit NG3028G073 / NG3029G073 for Version A Transceivers
For service purposes, the Transceiver Electronics Unit of the version A (transmitter up) can be
dismounted from the Gearbox and connected to the interconnection box by means of a cable set. For the
connection, see Figure 7-1 on page 104.
The order No. for the service kits are:
- X-Band: NG3028G073STR Order No.: 300004155
- S-Band: NG3029G073STR Order No.: 300004156
The service kits each consist of a cable and a dummy load.
WARNING:
The dummy load has to be connected before switching the

Transceiver to "ON"!
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7 Repair/Maintenance Gearboxes and Transceivers
7.1 Service Kit NG3028G073 / NG3029G073 for Version A Transceivers Technical Manual
115/230V AC
L1 TB12_1 brown
blue
N TB12_2
yellow/green
PE TB12_3
WAGO 721-103/026-000
24VMON (ONP) TB3_12 red 24VMON

TB3_14
24VGND (ONP) TB3_13 black 24VGND

TB3_15
WAGO 231-602
2
CAN0_A TB3_7 black CAN0_A
TB3_11 3
CAN0_B TB3_6 white CAN0_B
TB3_10 4
green GND
GND TB3_5 5
9
INTERCONNECTION BOARD
GE3044G206/216 10
11
ATTENTION! 12
X - Band: Service Kit
NG3028G073 STR
DUMMY LOAD Waveguide dummy load
SPINNER BN260306 AMP 532-2807
must be connected
S - Band: Service Kit before switching the
ztr1_177.eps
NG3029G073 STR
DUMMY LOAD transmitter to "ON"
SPINNER BN531309
Fig. 7-1 Connection of the service kit NG302XG073STR
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Technical Manual 7.2 Trouble-Shooting
7.2 Trouble-Shooting
7.2.1 Hints
In case the of problems during setting-to-work, the cabling should be checked again. All components
must be supplied with power.
- Read the system fault messages on the screen to get more information about the problem.
- Try to perform the self-check routines as described in the technical manual of the Display Electronics
Unit to localize the fault.
- If no radar video is displayed, the LEDs DS11, DS12, DS13 of the RDC indicate, whether the
incoming signal is correct.
7.2.2 System Faults
The system fault codes are displayed on the monitor together with a short description. To obtain more
information about the system faults and to display the existing faults, use the System Maintenance
Manager with the submenu Telemonitoring Data.
The system faults of the Telemonitoring Data screen are displayed in four columns. These columns are:
- Error
- Dev.
- SubDev.
- Info
The column "Error" shows the system fault number. The column "Dev." shows the device which is
causing the fault, and the column "SubDev." gives an indication for the defective subdevice, if possible.
The system faults are listed in the technical manual of the Display Electronics Unit.
7.2.3 Error 02279 and 04010 appear simultaneously
1. See the hints in the section "System Faults" in the technical manual of the Display Electronics Unit.
2. It may happen, that the adjusting screw of the HV supply switch (see pictures in Section 1.6.2) in
the Gearbox or bulkhead transceiver housing has become maladjusted. In this case the screw must
be adjusted and locked by means of loctite.
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7.2 Trouble-Shooting Technical Manual
7.2.4 Decreasing Working Range
If the radar working range is becoming weak, the microwave receiver is defective in many cases.
Some of the receivers offer a test point at which a monitor voltage can be measured. The following table
shows the different types of receivers and the permissible monitor voltages.
X-Band
Type of receiver
Older versions: No test point in existence
B3RX1612 (EEV) Current versions: 30...70 mV DC
NJT1946A (JRC) Typical voltage: 50 mV DC
S-Band
Type of receiver
B7RX1002 (EEV) 3.5 V DC ±0.5 V = O.K., 0.5 V DC = defective
NJS4310D 50 mV DC ±20 mV = O.K.
WARNING:
The reason for a defective microwave receiver can be a defect of the limiter. If this
is the case it may happen that the exchanged receiver will be damaged, too.
WARNING:
The test point of the receiver
NJT1946A is difficult to reach. It is
definitely advisable to switch off
the Transceiver before connecting
the measuring instrument. The
test point must not be short
circuited with assemblies around
the test points!
Test point
Assembly near
the test point
ztr1_193.jpg
Test point for monitor voltage of receiver

NJT1946A (JRC)
7.2.5 Defective Threads for the Gearboxes Cover Locking Screws
A repair kit with helicoils and tools can be ordered. See the spare parts lists in Section 7.9.
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Technical Manual 7.2 Trouble-Shooting
7.2.6 Humming Noise from the X-Band Gearbox GR3017
In rare cases, a humming noise is audible which is emitted from the Gearbox. In this case the modifica-
tion kit GR3017G040 (Order No. 390002382) can be ordered. The modification kit contains a rubber
gasket which can be mounted between the motor and the holder. The modification kit contains the modi-
fication instructions.
From serial No. 122-31580 on, the rubber gasket is mounted ex works.
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7.3 Software Update and Installation Technical Manual
7.3 Software Update and Installation
To update the radar software, follow the instructions in the technical manual of the Display Electronics
Unit.
7.4 Opening the Housings, Removing the Electronics Unit Carrier
7.4.1 Opening of the Bulkhead Transceiver Housing
WARNING
Before opening the housing, be sure, that the power supply for the RF-
unit is switched off. Mains supply may be present at the terminals!
The cover of the bulkhead housing is fixed with screws. The number of screws depends on the Trans-
ceiver version. Undo all screws and remove the cover. See Section 7.4.3 for removal of the Transceiver
Electronics Unit.
7.4.2 Opening of the Gearbox
WARNING
Before opening the Gearbox, be sure, that the power supply for the RF-
unit (version A only) and the motor is switched off. Mains supply may be
present at the terminals!
The cover of the Gearbox is fixed with screws. The number of screws depends on the Gearbox version.
Undo all screws and open the cover.
7.4.3 Swinging out the Electronics Unit Carrier
The Transceiver’s components are mounted on a carrier which is installed in the Gearbox (Transceiver
up, version A) or in the a bulkhead housing (Transmitter down, version B). The carrier is mounted by
means of hinges. When the screws (1) have been unscrewed, the carrier can be swung out.
For S-Band Transceivers, the coaxial cable to the Scanner must be released at the transceiver elec-
tronics before the carrier can be swung out.
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Technical Manual 7.4 Opening the Housings, Removing the Electronics Unit Carrier
For bulkhead versions (version B) the waveguide flange is located above the carrier. The four screws (8)
must be removed and the connector of the test oscillator must be disconnected (at J5 of the power supply
unit NG3028G202) before the carrier can be swung out.
3
1
ztr1_089.jpg
The carrier with locking screws The hinges of the carrier 2
6
ztr1_154.jpg
ztr1_090.jpg
4
5
The waveguide coupling The waveguide coupling (Gearbox)

(carrier) with bolts for with additional coupling flange for
version A, X-Band version A, X-Band
7
8
ztr1_155.jpg
Transceiver with additional coupling

flange, carrier closed
ztr1_624.jpg
The waveguide
coupling (carrier) with
bolts for version B
Fig. 7-2 Transceiver electronics unit
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7.4 Opening the Housings, Removing the Electronics Unit Carrier Technical Manual
7.4.4 Removing / Installing the Electronics Unit Carrier
Swing out the carrier as described in Section 7.4.3. Disconnect the cabling between the carrier’s compo-
nents and the Gearbox. Release the screws (1) and (2) to remove the carrier.
The carrier must be installed carefully. The flanges of the waveguides must fit as exactly as possible. The
flanges are equipped with two small bolts (4) each, to adjust them relative to each other. Place the carrier
with the Transceiver Electronics Unit in its position and fix it with the screws (1). Before tightening the
screws, adjust it to the right position so that the bolts of the waveguide flanges fit in the holes of the oppo-
site flange. Then tighten the screws (2) of the hinges.
Versions with an Additional Waveguide Coupling (X-Band, Transceiver Up only)

To improve the fit of the waveguide flanges, some systems have been equipped with an additional
waveguide coupling (5). To swing out the carrier, the screws (6) have to be unscrewed additionally.
Removing / Installing the Carrier:
Disconnect the cabling between the carrier’s components and the Gearbox. Release the screws (1),
(2) and (6) to remove the carrier.
The carrier must be installed carefully. The flanges of the waveguides must fit as exactly as possible.
The flanges are equipped with two small bolts (4) each, to adjust them relative to each other. Place
the carrier with the Transceiver Electronics Unit in its position and fix it with the screws (1). Before
tightening the screws, adjust it to the right position so that the bolts of the waveguide flanges fit in
the holes of the opposite flange. Then tighten the screws (6) of the additional coupling and (2) of the
hinges, in that order.
Assembling of a New Carrier:
The carrier must be installed carefully. The flanges of the waveguides must fit as exactly as possible.
The flanges are equipped with two small bolts (4) each, to adjust them to each other. Place the
carrier with the Transceiver Electronics Unit in its position and fix it with the screws (1). Release the
screws (3) and (7). Before tightening the screws, adjust it to the right position so that the bolts of the
waveguides flanges fit in the holes of the opposite flange. Then tighten the screws (6) of the addi-
tional coupling, (7) of the magnetron mounting plate and (2) of the hinges, in that order.
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7.4.5 Replacement of transceivers NG3028/29 by NG3040/41
Due to the fact that the new IMO radar performance standard MSC.192 (79) is into force since Juli 1st
2008, parts of the SAM Electronics radar systems have been redesigned. The X-Band and S-Band trans-
ceivers NG3028/NG3029 have to be replaced by the new models NG3040/NG3041 in order to fulfil the
requirements 1).
The installation is described for the X-Band Transceiver-Up version as an example. For X-Band Bulkhead
and S-Band transceivers the installation is very similar and can be performed as described in 7.4.3 and
7.4.4.
Required conversion kits:
X-Band 25 KW, Version A, Antenna/Mast, (Transceiver up) 390005671
X-Band 25 KW, Version A, Antenna/Mast,, (Transceiver up) 390005672
X-Band Version B, Bulkhead, (Transceiver down) 390005673
S-Band Transceiver up, Version A, Antenna/Mast, (Transceiver up) 390005674
S-Band Transceiver down, Version B, Bulkhead, (Transceiver down) 390005675
7.4.5.1 Gearbox X-Band up, 12,5/25 kW
Follow the next steps in order to exchange parts of the HF-waveguide. If you follow this description, there
will be no need to loosen and disconnect the contactor module !
Open the housing and remove the transceiver. Unscrew the test oszillator, take it off the waveguide and
put it beside carefully. Remove the five bolts (1) shown in the picture:
1)
If a system is not intended to fulfil the requirements of the new performance standards, no hardware must be changed. The software can
be upgraded anyway.
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The HF-waveguide can now be slid downwards a little bit and can be moved inside the housing. This
offers the possibility to unscrew the four bolts (2) on the HF-waveguide:
After this, the vertical part of the waveguide and the bracket can be taken out of the housing. The vertical
part of the waveguide will be used for the new installation again. It remains inside the housing. Take the
new horizontal waveguide part and assemble it to the vertical part. Start with the two bolts facing towards
you, with the other two bolts, fix the bracket again:
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Afterwards, the unit can be fastened in the housing again. Remember to adjust the coupling pin vertically
by means of the adjustment holes (3) in the bracket (Please refer to chapter 3.2.2.2 (X-Band) or 3.2.2.4
(S-Band) for further information, because the scanner must be removed for this step):
Now, the new front holder can be fastened (4). Fix the test oszillator (5) in a way that its coupling pin is
in the center of the hole in the waveguide. Use a tie-rap (6) in order to fasten the cables behind the
front holder:
6 4
Install the new transceiver as described in the

chapters above, set the new TCU to the same
settings as the original one (for example trans-
ceiver number, CAN-bus termination) and close
the housing. Stick the label enclosed in the
conversion kit on to the housing next to the black
label showing the material information:
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Unexpected behaviour of the components may occur if they are used with an
incorrect software version !
Before setting the new equipment to work, it is necessary to install the new soft-
ware version on the appropriate indicator electronics units. For this, please refer
to the operating instructions.
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Technical Manual 7.5 Fuses
7.5 Fuses
See Section 7.9 on page 135 for the order numbers of the spare parts.
Mains Input Unit (NG3028G204))

No. Rating
2 A slow blow (230 V)
F1 4 A slow blow (115 V)
2 A slow blow (230 V)
F2 4 A slow blow (115 V)
Power Supply Unit (Transceiver, NG3028G202)

No. Rating
F1 0.16 A slow blow
Start Unit 1
No. Rating
F1 1 A slow blow
Heating
No. Rating
F4 (X-Band) 2 A slow blow
F4 (S-Band) 2 A slow blow
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7.5 Fuses Technical Manual
Antenna Motor (F1...F3), Heating (F4)
X-Band
Nom.
Mains Fuse F1...F3/A F4/A rpm
current Power/W Motor
supply (slow blow) (slow blow) (nom.)
/A
1-ph/230 V Asynchronous motor
0.8 70 4 2 1430
50 Hz (3X14PD2523050)
0.8 70 4 2 1730
60 Hz (4X14PD2523060)
3-ph/230 V 2700/ Dahlander Asynchr. motor
1.15/0.55 180/70 6.3 2
50 Hz 1450 (5X32/4PD2523050)
3-ph/230 V 3330/ Dahlander Asynchr. Motor
1.05/0.52 180/70 6.3 2
60 Hz 1750 (6X32/4PD2523060)
50 Hz 1) 0.65/0.32 180/70 4 2 1450 (7X32/4PD2540050)
0.60/0.30 180/70 4 2
60 Hz 1750 (8X32/4PD2540060)
1)
also 3-ph/440 V, 60 Hz
S-Band
Nom.
Mains Fuse F1...F3/A F4 rpm
current/ Power/W Motor
supply (slow blow) (slow blow) (sync.)
A
5.5 900 10 2 1430
50 Hz (3S14PD2923050)
5.5 900 10 2 1730
60 Hz (4S14PD2923060)
4.2/3.2 1000/750 10 2
50 Hz 1450 (5S32/4PD2923050)
3.8/3.1 1000/750 10 2
60 Hz 1760 (6S32/4PD2923060)
50 Hz 1) 2.4/1.9 1000/750 6.3 2 1450 (7S32/4PD2940050)
2.2/1.75 1000/750 6.3 2
60 Hz 1760 (8S32/4PD2940060)
1) also 3-ph/440 V, 60 Hz
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Technical Manual 7.6 Exchange of Parts and Testing
7.6 Exchange of Parts and Testing
7.6.1 Exchange of the S-Band Scanner
See the table below for the possible combination of original part and spare part. The Scanner
GR3009G090 is the former version, the Scanner GR3021G090 is the current version of the S-Band
Scanner.
Transceiver/ Original Part Spare Part Procedure
Gearbox
Transceiver up GR3009G090 GR3009G090 See the installation instructions in Section 3.2 for
the installation of the Scanner.
Transceiver down GR3009G090 GR3009G090 See the installation instructions in Section 3.2 for
Transceiver up GR3009G090 GR3021G090 See section Section 7.6.1.1
Transceiver down GR3009G090 GR3021G090 See section Section 7.6.1.2
Transceiver up GR3021G090 GR3021G090 See the installation instructions in Section 3.2 for
Transceiver down GR3021G090 GR3021G090 See the installation instructions in Section 3.2 for
7.6.1.1 Transceiver Up (GR3009G090 shall be replaced by GR3021G090)
The modification kit GR3018G056 must be used. When the former

Coaxial cable
version of the Scanner is used (GR3009G090), the rotary joint is
located below the coupling pin in the hollow shaft. When the new Coaxial tube
Scanner (GR3021G090) is used, the rotary joint is located inside
the Gearbox, below the coaxial tube. The coaxial tube is turning
with the Scanner.
For the exchange of the Scanner perform as follows:
1. The Scanner must be removed. See the installation instruc-
Rotary joint
tions in Section 3.2. and proceed in reverse order to unmount
it.
2. Open the housing of the Gearbox. Flange
T-Holder
ztr1_661.jpg
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7.6 Exchange of Parts and Testing Technical Manual
3. The coaxial cable to the coaxial tube 3. 4.

must be released at the transceiver
electronics. Untighten the locking
screws of the carrier. The carrier can
be swung out then.
Clamp
4. The coaxial cable must be released at
the coaxial tube below the rotary joint.
It can be removed then.
5. Remove the clamp which fixes the
coaxial tube (2 screws).
ztr1_653.jpg
ztr1_654.jpg
6. The coaxial tube with the rotary joint
can be pushed upwards out of the
Gearbox (when the Scanner has been
removed beforehand). It is also possible to remove the blind plate in the Gearbox below the coaxial
tube. In this case, step 7. must be performed beforehand. The tube can then be led downwards out
of the Gearbox.
7. The shell which is located behind the clamp and the coaxial tube must also be removed.
8. The new coaxial tube (without the rotary joint) must be inserted from above before the new Scanner
is mounted.
9. The headless screws must be 9. 12. ... 11.
screwed in the flange. The rotary
joint must be inserted in the flange. It
can be fixed temporarily by means of
the two headless screws.
10. The new coaxial cable must be Flange Headless
protected by means of the insulating screws
foam tube (390002722) which
belongs to the modification kit. The
Rotary
foam tube must be cut along its joint
longitudinal axis beforehand.
ztr1_662.jpg
ztr1_663.jpg
11. The coaxial cable must be connected

at the rotary joint. It is advisable to
bend it so that the other end of the cable is in the correct position for the connection to the trans-
ceiver.
12. The unit consisting of rotary joint, flange and coaxial cable must be fixed at the coaxial tube (hex
wrench 32 mm and 27 mm).
13. The two T-holders must be fixed at 13. 15. Flange
the flange by means of the screws ring
(short) and washers. The even side
of the holders must face towards the T-holder
pulser. The screws must not be tigh-
centered
ened.
14. The T-holders must be fixed at the
threaded holes where the clamp was
fixed beforehand (longer screws).
The screws must not be tightened.
ztr1_664.jpg
ztr1_663.jpg
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15. Starting with the screws in the threaded holes, the screws must be tightened. It must be ensured,
that the connector for the Scanner at the upper end of the coaxial tube is centred.
16. IMPORTANT: Before the Scanner is mounted, 16.
the coaxial tube must be pulled down as far as
possible after the headless screws have been
released. There must be a distance of about
20 mm
20 mm between the connector at the upper side
of the coaxial tube and the flange ring of the
scanner holder.
17. The Scanner must be mounted as described in
Section 3.2.
18. The coaxial tube can be pushed upwards now,
ztr1_666.jpg
until the connector fits in its counterpart in the
Scanner.
19. The coaxial tube must be screwed manually into the Scanner. It must be tightened by means of a
hexagon socket head wrench or something similar which can be inserted in the holes of the ring
above the rotary joint.
20. The headless screws in the flange must be tightened to fix the rotary joint in the flange.
21. The carrier can be closed and the coaxial cable must be connected to the Transceiver.
22. The Gearbox must be marked by means of the label which is contained in the modification kit and
the performance of the radar must be checked. If the performance is not sufficient, the adjustments
for the Transceiver must be checked and corrected.
7.6.1.2 Transceiver Down (GR3009G090 shall be replaced by GR3021G090)
The modification kit GR3018G057 must be used. When the former version of the Scanner is used
(GR3009G090), the rotary joint is located below the coupling pin in the hollow shaft. When the new
Scanner (GR3021G090) is used, the rotary joint is located below the Gearbox, inside the flange. The
coaxial tube is turning with the Scanner.
Perform as follows:
1. The old Scanner must be unmounted.
2. Remove the clamp inside the Gearbox which fixes the coaxial tube (2 screws). The shell which is
located behind the clamp and the coaxial tube must also be removed.
3. The coaxial cable must be disconnected from the Gearbox. Remove the pipe clamps from the
bellows and pull the bellows down. The coax connector must be disconnected. The bellows can be
removed.
4. The coaxial cable must be disconnected from the Gearbox. Remove the pipe clamps from the
bellows and pull the bellows down. The coax connector must be disconnected. The bellows can be
removed.
5. The four screws of the connector flange at the Gearbox must be removed and the coaxial tube must
be pulled downwards out of the Gearbox.
6. The new Scanner must be mounted as described in Section 3.2.
7. The rotary joint must be fixed at the new coaxial tube (hex wrench 32 mm and 27 mm). The rotary
joint must be inserted in the flange. The headless screws for the rotary joint must not be tightened.
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8. The new coaxial tube with the rotary joint 9. 10.

and the flange at the lower side must be
pushed upwards into the Gearbox
9. The new flange must be mounted under the
Gearbox. The flange and the screws must
be smeared with silicone paste.
10. The coaxial tube must be screwed into the
Scanner by hand. Two flattenings have been
milled in the coaxial tube. The tube can be
tightened in the Scanner by means of a
ztr1_658.jpg
ztr1_659.jpg
19 mm spanner.
11. The headless screws in the flange must be 11.

tightened to fix the rotary joint.
12. The coaxial connector and the new bellows must be mounted.
13. The Gearbox must be marked by means of the label which is contained
in the modification kit and the performance of the radar must be
checked. If the performance is not sufficient, the adjustments for the
Transceiver must be checked and corrected.
ztr1_660.jpg
7.6.2 Exchange of the X-Band Scanner
If a new Scanner GR3020 must be mounted, the holder must be exchanged also. The holder which is
delivered with the spare part must be used. It is not permissible to use the holder of the defective
Scanner. The holder must be exchanged, regardless if the defective Scanner was of the type GR3020 or
GR3004. The serial numbers of the Scanner and the holder must be the same.
The installation of the Scanner is explained in Section 3.2.2.2 on page 50.
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7.6.3 Exchange of the X-Band Scanner in Transceiver Down Systems (Bulkhead Version)
In X-Band transceiver down systems, the Gearbox and the Scanner have been
adjusted with each other during manufacturing.
When the Scanner has been exchanged and the Gearbox has not been exchanged
by an accompanying spare part which has been adjusted to the new Scanner ex
works, it might be possible that the main bang is found as a nuisance by the oper-
ator. In this case it is necessary to perform an adjustment as described below.
The adjustment must be performed while the Scanner is turning. It is advisable to
prepare the adjustment procedure beforehand to reduce the range of work that must
be performed at the Gearbox while the Scanner is turning. 1
1. Open the Gearbox housing. The X-Band transmitter down rotary joint
GR3017G005 becomes visible. The slide screw tuner is mounted at the rotary
joint. Place a 5.5 mm wrench and suitable slotted screwdrivers for the screws (1)
and (3) in the Gearbox.
2. Select the corresponding Transceiver, set the Indicator to master and select the
2, 3
0.25 NM range.
3. The Trigger Delay must be in a properly adjusted condition. Otherwise the
adjustment must be performed by means of the System Maintenance Manager
menus as described in the Technical Manual of the Display Electronics Unit.
4. Set RAIN and SEA to 0.
5. Open the System Maintenance Manager Menus and select Service > Trans-
ceiver > Setting-to-Work. The video is shown without any digital correction, so
ztr1_651.jpg
that the main bang is not be suppressed.
6. Set the Video MBS Amplitude and the Video MBS Delay in the Video MBS
menu to 0 and save the values. Make a note of the original values as an initial 2 3
value for the adjustment in step 11.
7. Untighten the outer screws (1) slightly, so that the slide screw tuner can be
moved upwards and downwards with the smallest possible looseness.
ztr1_652.jpg
8. Move the slide screw tuner slowly until the position has been found, which
causes the smallest main bang in the display. Fix it in this position by means of
the screws (1).
9. Untighten the nut (2) by means of a 5.5 mm wrench and turn the screw (3) in or out to find the posi-
tion which causes the smallest main bang in the display. Leave the screw in this position and fix it
by means of the nut (2).
10. Repeat step 8 and 9 once.
11. Check the adjustment of the STC Delay and adjust the Video MBS Amplitude and Video MBS
Delay in the Video MBS menu.
12. Close the Gearbox and exit the System Maintenance Manager menus.
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7.6.4 Exchange of Toothed Belts / Motor
The X-Band Gearbox runs with two toothed belts; the S-Band Gearbox runs with one toothed belt. For
the exchange, the Gearbox must be opened. If only the larger belt of the X-Band Gearbox has to be
replaced, the motor does not have to be removed.
NOTE:
If the pulleys have been damaged by a defect toothed belt (scoring, incisions) the pulley must be
exchanged, otherwise the pulleys will damage the new toothed belt.
Exchange of the Larger Belt

Release the four screws marked in Figure 7-
3. The motor can be moved a few millime-
tres to slacken the belt. Disconnect the
azimuth pulse generator, unscrew the
bracket shown in Figure 7-4 and lift it a few
millimetres. The belt can be removed from
the pulleys and led through behind the
bracket. To install a new toothed belt, carry
out the instructions in reverse. Take care,
that the bracket does not get stuck under the
screw. It must be movable after the screw
has been tightened (see Figure 7-4).
The belt must be stretched by means of the
motor carrier, which can be moved if the four
screws have not been tightened. For the
tension of the belt, see Figure 7-6 on
page 123.
ztr1_069.jpg
Fig. 7-3 Motor carrier
3
plastic bushing
1 bracket
ztr1_608.eps
ztr1_067.jpg
Fig. 7-4 Exchange of the toothed belt
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Exchange of the Smaller belt (X-Band)

If both belts (in addition, the smaller belt of the X-
Band version) have to be changed, the motor
must be removed. Remove the screws marked in
Figure 7-3, take the belt from the motor and take
the motor out of the Gearbox. The motor can be
fixed with its own screws in the Gearbox during
the repair. To do this, turn the motor around its
vertical axis and fix the carrier with two screws in
the right-hand two holes of the four threaded
holes where the motor is usually mounted. To
slacken the small toothed belt, remove three of
the four screws on top of the motor marked in
Figure 7-5. Then turn the motor around the
remaining screw to release the tension of the belt.
Replace the belt and follow these instructions in
reverse. For the tension of the belt, see Figure
7-6 on page 123.
ztr1_068.jpg
Fig. 7-5 Exchange of a toothed belt
7.6.5 Tension of the Toothed Belts

ztr1_150.jpg
NOTE! GR3017O000 Rev. 02: GR3018O000 Rev. 03

Pay attention to the X-Band small belt = 5 mm (1st stage) S-Band = 8 mm
values of the belts’ X-Band large belt = 7 mm (2nd stage)
tension shown on the
right side. The toothed GR3017O000 Rev. 03 and GR3040: GR3018O000 Rev. 04 and
belts needs a defined X-Band small belt = 5 mm GR3041:
amount of slackness. from Serial No. 122-31580 on: as loose as possible S-Band = 8 mm
They must not be tight- (1st stage)
ened! X-Band large belt = 7 mm
(2nd stage)
Fig. 7-6 Tension of the belts (example: 2nd stage of X-Band Gearbox)
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7.6.6 Note about the Exchange of Motors (S-Band)
Two versions of S-Band motors with different lengths are in use. To make it possible to use both types
of motor, the pulley has a spacer block on one side. The pulley can be turned through 180° to adapt for
both versions of the motor.
7.6.7 Exchange of Capacitors for 1-ph Motors
The capacitors for the 1-ph motors are mounted at the side of the motor. The motor must be unmounted
(see Section 7.6.4) to exchange the capacitor.
The type of capacitor which is currently installed or delivered as a spare part has a metal enclosure. The
former types have plastic enclosure.
At X-Band radars, the former types of capacitors must be exchanged by a spare part kit, because the
cable connection must be modified.
Overview:
Spare part Spare part
Order No. Capacitor new (former version -> (current version ->
Motor (Motor complete) (ex works) current version), current version),
Order No. Order No.
S-Band
1-ph 230 V/50 Hz 1x 16µF 1x 16µF
5032954 2x 8 µF
(3S14pD2923050) 390004673 390004673
1-ph 230 V/60 Hz 1x 12 µF 1x 12 µF
5032284 1x 12 µF
(4S14pD2923060) 271168626 271168626
X-Band
Spare part kit
1-ph 230 V/50 Hz 1x 12 µF
5032953 1x 12 µF GR3017G055,
3X14pD2523050 271168626
No. 390004651
Spare part kit
1-ph 230 V/60 Hz 1x 10 µF
5032287 1x 10 µF GR3017G056,
4X14pD2523060 271178925
No. 390004652
Spare part kit
1-ph 115 V/60 Hz 1x 40 µF
5032288 1x 40 µF GR3017G057,
2X14pD2511560 271178924
No. 390004653
Exchange S-Band
The capacitors can be exchanged without additional material. The electrical connection and the mechan-
ical mounting are the same for the former types and the current types of capacitors.
NOTE:
The 230 V/50 Hz motor is delivered with two 8 µF capacitors. If one of them is defective, both must be
removed. One 16 µF capacitor is delivered as spare part and can be mounted instead.
Exchange X-Band
The electrical connection of the current types of capacitors is different. If the former type shall be
exchanged by the current type, one of the spare part kits must be used. Perform the exchange as
described in Figure 7-7.
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Before modification
1. Disconnect the Gearbox ~90 mm Capacitor

from mains. (former
brown version)
2. Disconnect the plug P2.
P2
3. Unmount the motor as cut
described in Section 7.6.4 blue
4. Unmount the capacitor.
5. Cut of the cable to the old

capacitor.
6. Remove the capacitor. to motor
7. Strip the insulation at the Modified connection

end of the cut wires.
Capacitor
8. Connect the wires to the termi- Original connector Spare part kit (current
nals of the spare part kit. The brown brown version)
colours must correspond. P2
9. Mount the capacitor. blue

blue
10. Mount the motor as described
in Section 7.6.4.
ztr1_674.eps
11. Adjust the tension of the terminals

toothed belts as described
in Section 7.6.5 to motor
10. Connect the plug P2
Fig. 7-7 Exchange of motor capacitor (X-Band, spare part kit)
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7.6.8 Shield Cover with Microwave Absorption Filling (S-Band, former version)
The current version of Gearboxes with the rotary

joint inside (Transceiver up) or below (Transceiver
down) the housing which must be used with the
Scanner GR3021G090 do not have shield cover.
Depending on the version, under the waveguide
connection to the coupling pin there is a shield
cover (1). The cover is clamped to the waveguide
by means of a U-shaped metal plate (2). The cover
is filled with a microwave absorption filling (3) which
should not be removed. 3
To dismount the shield cover, remove the U-shaped 1

metal plate. To fix the shield cover, press it upwards
along the waveguide to the gearbox housing and
push the U-shaped metal plate onto the waveguide
ztr1_112.jpg
to clamp the shield cover in position. 2
ztr1_113.jpg
Shield cover with absorption filling
7.6.9 Exchange of the Headmarker
7.6.9.1 X-Band
There are three versions of the Headmarker:

1. In X-Band Gearboxes GR3017 Rev. 03, the Headmarker is located near the waveguide outlet
coupling. Two versions of the Headmarker exist. The Headmarker itself is of the same type, but the
connectors are different. One version must be used if a Connection Board GR3017G200 Rev. - is
installed, the other one must be used if the Connection Board GR3017G200 Rev. 01 is installed
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(see the spare part list). The Headmarker must be exchanged by the spare part of the same type.
The adjustment must be performed by means of the System Maintenance Manger menus. The
Headmarker cannot be adjusted mechanically.
2. In X-Band Gearboxes GR3017 Rev. 03, where the Azimuth Pulser HEDS-5605 has still been
exchanged by means of the spare part kit GE3017G027, the Headmarker the Headmarker cannot
be replaced separately. The spare part kit GR3017G027 (Order No. 390002108) must be used
again. A technote with a description of the exchange is delivered with the spare part kit. The adjust-
ment must be performed by means of the System Maintenance Manger menus. The Headmarker
cannot be adjusted mechanically.
3. In X-Band Gearboxes GR3017 Rev. 05 the combined azimuth pulser and headmarker is installed.
To replace the headmarker, the complete set of cables and pulsers GR3017G038 (Order No.
390002188) must be used. The adjustment must be performed by means of the System Mainte-
nance Manger menus. The Headmarker cannot be adjusted mechanically.
7.6.9.2 S-Band
Two versions of the Headmarker exist. The Headmarker itself is of the same type, but the connectors at
the cable are different. One version must be used if a Connection Board GR3017G200 Rev. - is installed,
the other one must be used if the Connection Board GR3017G200 Rev. 01 is installed (see the spare
part list). The Headmarker is located near the waveguide outlet coupling. It can be replaced by the spare
part of the same type. The adjustment must be performed by means of the System Maintenance Manger
menus. The Headmarker cannot be adjusted mechanically.
7.6.10 Exchange of Azimuth Pulse Generator
7.6.10.1 X-Band Azimuth Pulse Generator
HEDS-5605
If the pulser HEDS-5605 is defective, it must be replaced by a new pulser which is available with the
Modification Kit GR3017G027, Order No. 390002108. The Modification Kit contains a Technote which
describes the procedure of the exchange.
If this spare part becomes defective it must be exchanged again by means of the Modification Kit
GR3017G027. In this case it is not necessary to exchange the slotted wheel again.
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Combined Azimuth / Headmarker Pulse Generator

The spare parts are delivered as a
cable set GR3017G038, Order No.
390002188, with the connected
pulsers. If one of the pulsers is
Screws M2.5
defective, the complete cable set
with both pulsers must be
exchanged. The pulsers are
mounted on a holder which is fixed
by means of screws. To remove the
cable set with the pulse generators,
ztr1_649.jpg
the holder must be unscrewed and
the cables must be disconnected at
the Connection Board Transceiver
GR3017G200.
To mount the spare part, proceed
in reverse order.
The slotted wheel is mounted
below the hollow shaft by means of
three screws M 2,5. If the slotted
Holder
wheel is mechanically damaged, it
can be exchanged. The waveguide
must be removed for this purpose.
ztr1_650.jpg
Fig. 7-8 Combine Pulse Generator
7.6.10.2 S-Band Azimuth Generator
Disconnect the pulser cable at the connection board. Then unscrew the flange nut and exchange the
pulser (see Figure 4-12 on page 71).
The distance between the pulser’s end face and the pulser disk must be adjusted. For further information
about the adjustment, see page 70 on page 70. It is important to adjust the correct distance between the
pulser and the chopper wheel. The distance depends on the pulser version.
7.6.11 Exchange of Magnetron
Switch off the radar. Switch off the mains supply for the Gearbox and check if it is really free of voltage.
(The man aloft switch below the Gearbox switches the power supply for the motor only). The different
types of magnetron are fixed with 4...6 screws. To exchange the magnetron, remove the screws by
means of non magnetic tools and replace it with a new one.
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NOTE:
Make sure that the magnetron cables are laid and fixed in a way that it does not come in direct contact
to the housing.
NOTE:
To avoid possible dangerous overloads of the magnetron, the following procedure must be performed.
The same works have to be performed, if the Modulator has been exchanged. Follow the instructions
below:
1. Make sure that the transceiver is free of voltage!
2. Change the position of the switch S2/3 on the TCU regardless of the current position (see Section
4.5.7 from page 84 onwards) of the switch.
3. The switch must remain in this position until the magnetron is changed the next time.
4. After power on of the Transceiver the TCU program recognizes the modified DIP switch setting and
loads default (safe) Imag values.
5. Enter the System Maintenance Manager.
6. Click on Service and enter the password.
7. Click on Service and confirm with Continue. Click on Transceiver > Advanced Settings > Magn-
etron.
8. Select the 12 NM range.
9. Follow the instructions in the technical manual of the Display Electronics Unit for the magnetron
current adjustment.
NOTE:
For the shortest pulse length enlarged deviations have to be tolerated.
10. For the adjustment of the magnetron heating voltage, see Section 4.5.1.2 on page 75.
11. The new TCU parameters must be loaded to all connected Indicators
7.6.12 Exchange of Limiter
7.6.12.1 X-Band Limiter
1. Remove the magnetron (see Section 7.6.11) to gain access to the screws of the circulator.
2. Unscrew the two recessed head screws and take care, that the circulator does not fall down.
3. Disconnect the coaxial cable between receiver and IF-amplifier (see Figure 4-18 on page 78).
4. Unsolder the coaxial cable at the limiter and unscrew the shield contact.
5. Remove the receiver and the circulator. Both are mounted at the limiter by means of 4 screws.
6. Proceed in reverse order to mount the new limiter.
7. Perform a test of the radar. Further adjustments are not necessary.
7.6.12.2 S-Band Limiter
1. Disconnect the coaxial cable between receiver and IF-amplifier (see Figure 4-20 on page 80).
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2. The receiver is mounted on the Limiter by means of four hexagon socket screws. Remove the
screws to dismount the receiver.
3. Unsolder the coaxial cable at the Limiter and unscrew the shield contact.
4. The Limiter is mounted on the T-junction by means of four hexagon socket screws. Remove the
screws to dismount the Limiter.
5. Proceed in reverse order to mount the new limiter.
6. Perform a test of the radar. Further adjustments are not necessary.
7.6.13 Exchange of TCU
The TCU contains all transceiver parameters. All these parameters are also stored in the IDE memory
module and they should be stored on a diskette. If it is not certain, that the parameters stored on the
diskettes are up-to-date, it is advisable to make a back-up (if possible) and to use the parameters which
are stored in the IDE memory module.
To exchange the TCU, switch off the system. Disconnect the Transceiver from the ship’s mains. Open
the Gearbox (Version A) or the transceiver bulkhead housing and swing out the carrier.
1. Mark the coaxial cables to be able to connect them at the correct connectors again. Disconnect all
cables from the TCU.
2. Unscrew the 6 screws of the pcb and pull it carefully out of its connector.
3. Set the jumpers and switches of the new TCU to the same positions as on the defective pcb.
4. Push the new TCU into the connector and fix it by means of the screws. Connect the cables.
5. Check the software version of the component by means of the maintenance menus of the Display
Electronics Unit. The software version of the component must be compatible with the software
versions of all other components. The software version of the component must be compatible with
the software versions of all other components. If this is not the case, a pcb software update must be
performed as described in the technical manual of the Display Electronics Unit. For further informa-
tion about the software versions, see the "Software Change Notes" and "Technotes" (also available
via internet).
6. Switch on the system and store the parameters from the IDE memory module or hard-disk (MULTI-
PILOT) to the TCU (do not reload the parameters from the TCU into the IDE memory module!). If it
is certain that the data is up-to-date, the parameters can also be restored from the back-up diskette.
7. Use the Service menu of the System Maintenance Manager to perform the transceiver adjust-
ments. See the technical manual for the Display Electronics Unit for further information. All adjust-
ments of the Setting to Work menu must be performed. Every adjustment must be stored by means
of the Save button. The parameters are stored in the IDE memory module, the hard-disk (MULTIP-
ILOT) and in the TCU.
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7.6.14 Exchange of Modulator NG3028G203/206/207
The Modulators NG3028G203/206 and NG3028G207 differ only in a few components. The method of
exchange is the same for all versions. The Modulator NG3028G206/206 is adjusted and configured by
means of potentiometers and/or jumpers, NG3028G207 is adjusted and configured by means of jumpers.
Set the jumpers of the new Modulator in the same way as the jumpers of the defective Modulator. The
adjustments of the bias and the heating voltage must be performed after the exchange. The way of
adjustment is different for the various revisions of the Modulator. The potentiometers for the heating
voltage have been replaced by jumpers. See Section 4.5.1 from page 73 on for further information
1. To remove the Modulator, the cable to the magnetron must be disconnected. In former versions, the
magnetron cable is soldered directly to the transformer of the Modulator. In the present version, the
cable is connected at terminals on a terminal board.
2. Remove the 8 screws of the Modulator and pull the pcb out of the connector J1.
3. Set the jumpers of the new Modulator to the same position as on the defective pcb (for identical pcbs
only, otherwise, see Section 4.5.1 from page 73 on).
4. Push the Modulator carefully into the connector J1 and fix it by means of the screws.
5. Connect the magnetron to the Modulator by means of the two connectors or solder it. If the magne-
tron or Modulator is not equipped with terminals, it is possible to cut off the connectors and to solder
the cable.
6. Do not operate the system before the following adjustments have been performed.
- The same adjustments must be performed as for the exchange of the magnetron. See Section
7.6.11 from page 128 onwards.
- Afterwards the magnetron current must be adjusted as described in the technical manual of the
Display Electronics Unit.
7.6.15 Exchange of the IF Amplifier NG3018G022/080
To replace an IF amplifier, the cables must be disconnected and the screws must be unscrewed to
remove the amplifier. To mount the new amplifier proceed in reverse order. The adjustment of the video
amplitude should be checked as described in Section 4.5.5 on page 82. The parameter Video Anti
Clutter Sea (System Maintenance Manager, see the technical manual of the Display Electronics Unit)
has to be set to On.
7.6.16 Exchange of the HF Unit NG3028G205
To replace an HF-Unit, the cables must be disconnected and the screws must be unscrewed to remove
the unit. To mount the new part, proceed in reverse order. The adjustment of the video amplitude should
be checked as described in the technical manual of the Display Electronics Unit.
7.6.17 Exchange of the Power Supply Unit NG3028G202
The power supply unit is configured by means of jumpers. No adjustments have to be performed after
the exchange.
1. To remove the power supply unit, disconnect all cables.
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2. Remove the 6 screws of the pcb.

3. Set the jumpers of the new power supply unit to the same positions as on the defective pcb.
4. Fix the new pcb by means of the six screws and connect all cables.
7.6.18 Exchange of Connection Board (Transceiver)
Be sure, that the Transceiver is disconnected from mains (RF unit and motor)!
Only one version for X-Band and S-Band exists. The board can be exchanged without any prerequisites
and no adjustments must be performed afterwards.
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Technical Manual 7.7 Maintenance
7.7 Maintenance
Maintenance Schedule
The maintenance of the radar is limited to
Work Interval Remarks
Magnetron working hours can be checked
by means of the Maintenance Manager:
Every 12 month is suggested. Click on the buttons MENU, UTILITIES
Average working life for and MAINTENANCE, answer the safety-
Exchanging the magnetron - X-Band: about 6000...8000 h related question and click on the index
- S-Band: about 9000...16000 h card Telemonitoring Data, and then click
on Versions. Magnetron working hours
are displayed in the text.
The belt should be checked
Exchanging the toothed belt during the exchange of the
magnetron.
Every 3 month, depending on Nevertheless it makes sense to check the
Exchanging or cleaning the filter the dustiness of the environ- pad whenever maintenance or repair work
pad of the Display Electronics ment; operators maintenance has to be done. See the technical manual
Unit work of the Display Electronics Unit.
Checking the housing fan and the Whenever maintenance or See the technical manual of the Display
CPU fan of the electronics unit repair work has been done Electronics Unit.
Exchanging the CMOS backup See the technical manual of the Display
Every 5 years.
battery Electronics Unit.
Whenever maintenance or
Checking the seal of the Antenna repair work has been done at
Unit the Gearbox
It is not necessary to exchange the gear lubricant oil.
7.7.1 Magnetron
It is usual to exchange magnetrons every 12 months. The condition of the magnetron can be checked by
means of the performance monitor. Magnetrons are aging even when the radar is not in use or the magn-
etron is stored. It is advisable not to keep magnetrons in stock for a longer period of time. Their life is
reduced during storage, too.
The magnetron’s working hours can be checked by means of the working time meter, which can be read
on the Indicator, see Section 7.6.11. After the magnetron has been exchanged, the working time meter
must be reset.
If the magnetron is exchanged it is advisable to check also the belt. See Section 7.7.2 for further infor-
mation.
7.7.2 Belt Drive, Toothed Belts
The belts have to be checked every time the magnetron is exchanged. The belts should be checked for
mechanical damages as fissures and fractures on the surface and for visible parts of the weft, especially
at the edges. If such damages are visible, the belts must be exchanged.
See Section 7.6.4 for instructions about the exchange of the belts. If the pulleys are damaged, they have
to be exchanged, too.
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7.8 Cleaning of the Antenna Unit Technical Manual
7.7.3 Sealing of the Antenna Unit
The sealing between the door and the Antenna Unit housing should be smeared with silicone paste (order
No. 567-0152). This will prevent corrosion at the Antenna Unit housing along the line where the varnish
ends. The sealing is smeared with paste ex works and must be smeared again if the paste has been
washed out.
7.8 Cleaning of the Antenna Unit
IMPORTANT
Do not clean the Antenna Unit with a high-pressure cleaner!
The water and the detergents will pass the seals and drop
into the interior. This can cause corrosion.
134 ED3051G442 / 04 (2008-07)

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Technical Manual 7.9 Spare Parts
7.9 Spare Parts
7.9.1 Spare Part Concept
Most of the components in the Display Electronics Unit are parts which cannot be serviced. In the case
of a defect, the complete part must be exchanged.
7.9.2 Spare Part List
Some of the components of the Display Electronics Unit in particular will be modified at short intervals,
so that it is likely that it will not be possible to deliver spare parts which are absolutely identical to the
original part. In such cases, a technote for the exchange is delivered with the spare part and new versions
of components are added to this manual as soon as possible.
S-Band Gearbox GR3018

Part Order No.
Performance Monitor Amplifier (GR3018G201) 2871647
Contactor Module complete (GR3018G001) 271167808
Connection Board Transceiver (GR3017G200) 2869022
Drive Unit (including Motor), 3-ph, 400 V, 50 Hz (440 V, 60 Hz), (GR3018G032), Gearbox Rev.
03 1) 300004350
Drive Unit (including Motor), 3-ph, 400 V, 60 Hz (GR3018G033), Gearbox Rev. 03 1) 300004351
Motor Capacitor for Motor 1/ph 230 V/50 Hz (3S14pD2923050), 16 µF 390004673
Motor Capacitor for Motor 1/ph 230 V/60 Hz (4S14pD2923060), 12 µF 271168626
Transformer 115 V/230 V (4-43867-W32-007)) 300004151
S-Band Slotted Array Scanner 14 ft (GR3009G090) (former type) 1763214
S-Band Slotted Array Scanner 14 ft (GR3021G090) (current type) 390001677
Modification Kit (GR3018G057) Transceiver Down for Gearbox GR3018O000, necessary for 390002794
mounting the current type of Scanner GR3021G090)
Modification Kit (GR3018G056) Transceiver Up for Gearbox GR3018O000, necessary for 390002793
mounting the current type of Scanner GR3021G090)
Array Holder (F2815022) 300004804
Temperature Switch for Heating (R28 03 PN 111032) 5148185
Heating resistor for Heating (6050221) 5379544
Start Unit 2 pcb (GR3018G210) 300004615
High load resistor for Start Unit 2 (BRQ-22R0-10-L), 300 W (400 V mains supply) 300004214
High load resistor for Start Unit 2 (BRQ-10R0-10-L), 300 W (230 V mains supply) 300006157
Fuse for Start Unit, F1, 1.0 A, 250 V, slow blow (127-2-IEC-3-T1L) 5070561
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7.9 Spare Parts Technical Manual
Part Order No.

Azimuth Pulse Generator (9962-4200) 300004129
Gearbox S-Band, 50 Hz (G2815101) 300004629
Gearbox S-Band, 60 Hz (G2815102) 300004630
Power Contactor 24 V/DC (3TG10 01-0BB4) for GR3018G001 271167339
Set for 1 phase motor 230 V/50 Hz (start cap. 80 µF/250 V, working cap. 10 µF/400 V, relay) 271168627
Rotary Shaft Seal (Simrit) 65x100x10 mm 271168656
Deep groove ball bearing 608-2RS DIN 625 271168642
Azimuth Pulse Generator HEDS-5605 F13 (rarely used) 271168643
O-Ring 274x3 mm NBR70 DIN 3771 (in Gearbox cover) 271168659
V-Seal (circular, for the gearbox top cover) 271168660
Round Sealing (in carrier) 271168661
Synchronous Pulley AT5/30-2 on motor shaft, for Gearboxes Rev. 03 300004866
Synchronous Pulley HDT-5M/30-0, on motor shaft, for Gearboxes Rev. 04 300004854
Threaded Bolt DIN 913-M5x5-A2 271168663
Hallsensor (Headmarker) for Connection Board GR3017G200 Rev. - 271168664
Hallsensor (Headmarker) for Connection Board GR3017G200 Rev. 01 (coded plugs) 300005833
EMC Sealing (6.4x4.8 mm) 271168650
Synchronous Pulley AT5/77-0 (50 Hz), for Gearboxes Rev. 03 300004867
Synchronous Pulley HTD-5M/78-2 (50 Hz), for Gearboxes Rev. 04 300004855
Toothed Belt (50 Hz) 25AT5-660, for Gearboxes Rev. 03 300004843
Toothed Belt (50 Hz) CXP HDT 665-5M-25, for Gearboxes Rev. 04 300004859
Synchronous Pulley AT5/93-0 (60 Hz), for Gearboxes Rev. 03 300004868
Synchronous Pulley HTD-5M/93-2 (60 Hz), for Gearboxes Rev. 04 300004865
Toothed Belt (60 Hz) 25AT5-710), for Gearboxes Rev. 03 300004844
Toothed Belt (60 Hz) CXP HTD 710-5M-25, for Gearboxes Rev. 04 300004860
Fuse Heating S-Band, F4, 2 A, slow blow, 5x20 5071042
Fuse Heating S-Band, F4, 2 A, slow blow, 6.3x32 300004620
Fuses for motor (5x20 mm, slow blow) 6.3 A 5071038
10.0 A 5071015
Fuses for motor (6.3x32 mm, slow blow) 6.3 A 300004349
10.0 A 300004621
Coaxial tube Transceiver up for Gearbox GR3018Axxx 390002771
Coaxial Tube Transceiver down for Gearbox GR3018Axxx 390002772
Coaxial tube Transceiver up (GR3018G002) for Gearbox GR3018O000 2770923
Coaxial tube Transceiver down (GR3018G005) for Gearbox GR3018O000 2770924
Rotary joint for Transceiver GR3018Axxx up and down 390002528
Flange for rotary joint mounting, Transceiver GR3018Axxx down 390002783
Flange for rotary joint mounting, Transceiver GR3018Axxx up 390002781
Coaxial cable (internal waveguide) Transceiver GR3018Axxx up 390002786
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Part Order No.

Repair Kit Helicoil for gearbox threads (threads for cover locking nuts) 300006146
Modification kit for new transceiver NG3041 S-Band Up 390005674
Modification kit for new transceiver NG3041 S-Band Down 390005675
1)
The Drive Unit will be delivered with a HTD pulley, suitable for Gearboxes Rev. 04. For Gearboxes Rev. 03 with AT5 pulleys,
the pulley must be exchanged for the original pulley.
X-Band Gearbox GR3017

Part Order No.
X-Band Gearbox, Version A (up) without Motor, Transceiver, Heating; 60 Hz (GR3017G050) 300005742
Contactor Module complete (GR3017G001) 2777089
Connection Board Transceiver (GR3017G200) 2869022
Conversion Kit for belt drive of the small belt (fixing of pulley, see Technote) (GR3017G022) 300004497
Drive Unit (including Motor), 1-ph, 230 V, 50 Hz (GR3017G013), Gearbox Rev. 02 1)
300004228
Drive Unit (including Motor), 1-ph, 230 V, 60 Hz (GR3017G014), Gearbox Rev. 02 1) 300004229
Drive Unit (including Motor), 3-ph, 400 V/50 Hz, (440 V, 60 Hz) (GR3017G015),
Gearbox Rev. 02 1) 300004230
Drive Unit (including Motor), 3-ph, 400 V, 60 Hz (GR3017G016), Gearbox Rev. 02 1) 300004231
Drive Unit (including Motor), 3-ph, 230 V, 50 Hz (GR3017G017), Gearbox Rev. 02 1)
300004232
Drive Unit (including Motor), 3-ph, 230 V,60 Hz (GR3017G018), Gearbox Rev. 02 1)
300004233
Drive Unit (including Motor), 3-ph, 400/440 V, 50/60 Hz (GR3017G032), Gearbox Rev. 02 1) 300004900
Spare part kit GR3017G055 for motor capacitor for motor (1-ph 230 V/50 Hz 3X14pD2523050), 390004651
12 µF (replacement of capacitors with plastic enclosure, former version)
Motor capacitor for motor (1-ph 230 V/50 Hz 3X14pD2523050), 12 µF (replacement of capaci- 271168626
tors with metal enclosure, current version)
Modification Kit (humming noise) (GR3017G040) 390002382
Transformer 115 V/230 V (4-120073) 300004739
X-Band Performance Monitor Amplifier (GR3017G201) 2869021
X-Band Gearbox (G2814101) 5925287
Power Contactor 24 V DC (3TG10 01-0BB4) for GR3018G001 271167339
Fanwheel for X-Band Motors 271168624
Synchronous Pulley AT5/70-0, 2nd stage, for Gearboxes Rev. 02 300004865
Synchronous Pulley HTD-5M/70-0, 2nd stage, for Gearboxes Rev. 03 300004853
Toothed Belt 16AT5-500 (motor gear shaft to gear shaft), for Gearboxes Rev. 02 300004842
Toothed Belt CXP HTD 500-5M-16 (motor gear shaft to gear shaft), for Gearboxes Rev. 03 300004858
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Part Order No.

Deep groove ball bearing (608-2RS DIN 625) 271168642
Azimuth Pulse Generator (HEDS-5605 F13) in Gearboxes Rev. 03: Must be replaced by 390002108
means of the spare part kit GR3017G027, Order No. 390002108 (see page 127)
Combined Azimuth / Headmarker Pulse Generator (Cable Set with both pulsers, GR3017G038) 390002188
for Gearboxes Rev. 04
Combined Azimuth / Headmarker Pulse Generator (Slotted Disk, GR3017T035) 300006087
Combined Azimuth / Headmarker Pulse Generator (Holder, GR3017T036) 300006089
O-Ring 190x3 mm NBR70 DIN 3771 271168644
Adjusting Washer 80x100x0.1 mm, DIN 988 271168645
Adjusting Washer 80x100x0.3 mm, DIN 988 271168646
V-Seal (circular, for the Gearbox top cover) 271168647
O-Ring 85x3.5 mm 271168648
Headmarker for Connection Board GR3017G200 Rev. - (see page 126) 271168649
Headmarker for Connection Board GR3017G200 Rev. 01 (coded plugs) (see page 126) 300005832
EMC Sealing (6.4x4.8 mm) 271168650
Deep groove ball bearing (6202-2RS DIN 625) 271168651
Synchronous Pulley AT5/18-2 (2nd stage), for Gearboxes Rev. 02 300004864
Synchronous Pulley HTD-5M/18-2 (2nd stage), for Gearboxes Rev. 03 300004852
Synchronous Pulley AT5/18-2 (motor shaft), for Gearboxes Rev. 01 300004862
Synchronous Pulley HTD-5M/18-0 (motor shaft), for Gearboxes Rev. 02 300004850
Synchronous Pulley AT5/37-0 (1st stage), for Gearboxes Rev. 01 300004863
Synchronous Pulley HTD-5M/37-2 (1st stage), for Gearboxes Rev. 02 300004851
Toothed Belt 10AT5-300 (motor shaft to motor gear shaft), for Gearboxes Rev. 01 300004841
Toothed Belt CXP HTD 300-5M-12 (motor shaft to motor gear shaft), for Gearboxes Rev. 02 300004857
Slotted Array 5 ft with holder (GR3004G150) can be replaced by GR3020G150 1666890
Slotted Array 8 ft with holder (GR3004G160) can be replaced by GR3020G160 1666891
Slotted Array 5 ft with holder (GR3020G150) 390000211
Slotted Array 8 ft with holder (GR3020G160) 390000235
Fuse Heating X-Band, F4, 2 A, slow blow, 5x20 5071042
Fuse Heating X-Band, F4, 2 A, slow blow, 6,3x32 300004620
Fuses for motor (5x20 mm, slow blow)
4.0 A 5073585
6.3 A 5071038
Fuses for motor (6.3x32 mm, slow blow)
4.0 A 300004240
6.3 A 300004349
10 A 300004621
Waveguide Set (GR3017G002) 2768491
Waveguide Set (GR3017G005) 2768488
Repair Kit Helicoil for gearbox threads (threads for cover locking nuts) 300006146
Retrofit kit for Heating (GR3017G060) 390000356
Exchange/Upgrade Kit for former versions of the heating (GR3017G070) 390000358
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Part Order No.

Modification kit for new transceiver NG3040 X-Band Up 390005671
Modification kit for new transceiver NG3040 X-Band Up 390005672
Modification kit for new transceiver NG3040 X-Band Down 390005673
1)
The Drive Unit will be delivered with a HTD pulley, suitable for Gearboxes Rev. 02. For Gearboxes Rev. 01 with AT5 pulleys,
the pulley must be exchanged for the original pulley.
S-Band Transceiver NG3029

Part Order No.
S-Band Transceiver 30 kW 300003315
Waveguide (NG3029G008) 2771022
Microwave Receiver (NG3029G013) 300004044
Test Oscillator (NG3029G014) 300004096
Cable Set Transceiver (NG3029G006) 2774223
Magnetron M1302L (30 kW) 5227611
Magnetron MG5223 (30 kW) 5227610
Microwave Limiter (B3LT1008) 5227664
Microwave Limiter Kit (B3LT1023) 300004757
Toroidal Core Transformer (NG3029G007) 5040581
TCU (NG3028G201) 2861144
Transceiver Power Supply Unit (NG3028G202) 2859950
IF Amplifier (NG3028G080) 300005511
Spare part kit NG3029G049 for (IF Amplifier NG3028G080, TCU, cables) 390000590
Mains Input Unit (NG3028G204) 2869024
Modulator 25 kW (NG3028G206) 2870026
HV Supply Switch (Interlock) 300003634
Transformer for Modulator 25 kW (NG3028G063) 300004121
Fuse Mains Input Unit, F1, F2 (115 V), 4.0 A, slow blow 5073585
Fuse, Mains Input Unit, F1, F2 (250 V), 2.0 A, slow blow 5071042
Fuse, Transceiver Power Supply Unit, F1, 0.16 A, slow blow 271250056
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X-Band Transceiver NG3028

Part Order No.
Transceiver 25 kW 300003314
Transceiver 12.5 kW 300003313
TCU (NG3028G201) (see the Technotes, Ferrite Sleeve 5049360 needed) 2861144
Transceiver Power Supply (NG3028G202) 2859950
Modulator 12.5 kW (NG3028G203) 2855249
Modulator 25 kW (NG3028G206) 2870026
Toroidal Core Transformer (NG3028G007) 5040580
X-Band Test Oscillator (NG3028G008) 2772328
IF Amplifier (NG3028G080) 300005511
Spare part kit NG3028G056 for (IF Amplifier NG3028G080, TCU, cables) 300004890
Transformer for Modulator (NG3028G063) 300004121
Magnetron (MG5459): M1475A must be used instead 300005152
Magnetron (MG5245, NG3028G070): MSF1425A must be used instead 300004122
Set of Cables for X-Band Transceiver (NG3028G025) 2771535
Magnetron (M1475A, NG3028G072) 300004124
Magnetron (MSF1425A, NG3028G071) 300004123
Microwave Limiter Kit (B3LT1654) 5227662
HV Supply Switch (Interlock) 300003634
Mains Input Unit (Transceiver Power Switch, NG3028G204) 2869024
Receiver (NJT1946A) 5931754
Circulator (NJC3901B) 5938073
Ferrite Sleeve (for TCU connection) 5049360
Tie Wrap (for Ferrite Sleeve 5049360) 5361362
Fuse, Transceiver Power Supply Unit, F1, 0.16 A, slow blow 271250056
X-Band Gearbox GR3040

Part Order No.
TRANSFORMER 300004739
CONTACTOR MODULE X-BAND 2777089
HS05-CONNECTION 2869022
Contactor;power-;24VDC__POWER CONTACTOR 24V/DC HIKO: 3S+1Ö 271167339
Waveguide, X-Band Up 390005420
WAVEGUIDE; X-BAND DOWN 2768488
Ersatzgetriebe X-Up, R1100/2008 390006102
Replacement Gearbox; X-Band Down 390004974
Complete driving 1AC 230V/50Hz, X-Band 300004228
Complete driving 1AC 230V/60Hz 300004229
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Part Order No.

Complete driving 3AC400/440V-50/60Hz__drawn in GR 3017 G015 SGZ 300004230
Complete driving 3AC 400V/60Hz__drawn in GR 3017 G 015 SGZ 300004231
5ft. X-Band scanner 1666890
8ft. X-Band scanner 1666891
Mast installation material, X-Bd Gearbox 390004674
AS04-P.-M. AMPL. X-BAND 2869021
SENSORKIT,OPB480T11,OPB916BOC; X-BAND 390002188
Fan wheel 271168624
Toothed wheel HTD-5M/70-0 1.4301__FOR X-BAND-2.-STEP 300004853
Toothed wheel HTD-5M/18-2 1.4301__F.X-BAND-2.-STEP;WITH TWO FLANGED WHEEL 300004852
Toothed wheel HTD-5M/18-0 1.4301__FOR X-BAND-1.-STEP 300004850
Toothed wheel HTD-5M/37-2 1.4301__F.X-BAND-1.-STEP;WITH TWO FLANGED WHEEL 300004851
Toothed belt CXP HTD 500-5M-16__F.X-BAND-2.-STEP; CONTI SYNCHROFORCE 300004858
Toothed belt CXP HTD 300-5M-12__F.X-BAND-1.-STEP, CONTI SYNCHROFORCE 300004857
Shaft seal__GR3017 271168639
O-Ring 190 x 3__GR3017 271168644
O-Ring 85x3,5__GR3017 271168648
V-Seal (B+S)__GR3017 271168647
RF-Sealing (Altoflex)__GR3017 271168650
Ball bearing__GR3017 271168642
Ball bearing__GR3017 271168651
Shim ring 80x100x0,3__GR3017 271168646
Shim ring 80x100x0,1__GR3017 271168645
FUSE LINK__2AT/440V/6,3X32MM 300004620
Fuse link;T2A;5x20 5071042
FUSE LINK__6,3AT/440V/6,3X32 300004349
Fuse link;T0,16A;5x20 271250056
FUSE LINK__4AT/440V/6,3X32 300004240
Transformer 1ph, I:115V, O:230V, 400 VA__IN AC 115 V, OUT AC 230 V / 0,4 KVA 300004739
Repair kit; HeliCoil plus__HELICOILE AND TOOLS 300006146
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S-Band Gearbox GR4041

TRANSFORMER 300004151
START UNIT 2, AC400V__WITH TCU REV.05 OR NEWER 300004309
Start Unit 2, AC230V 300006156
HS08-SAN__START UNIT 2 300004615
High Load Resistor__22 OHM, 300W PERMAN. O. 3KW PULSE POWER 300004214
High Load Resistor__10 OHM, 300W PERMAN. O. 3KW PULSE POWER 300006157
14 ft. S-Band Scanner, Type GR3009G090 1763214
S-Band Antenna holder, wide 390003892
Mast installation material, S-Bd Gearbox 390004675
CONTACTOR MODULE S-BAND 271167808
HS05-CONNECTION 2869022
Contactor,power-,24VDC__POWER CONTACTOR 24V/DC HIKO: 3S+1÷ 271167339
GEARBOX S-BAND / 50 HZ__BASIC VERSION, SPEC.: GR3018O000 SN 300004629
GEARBOX S-BAND 60HZ__BASIC VERSION, SPEC.: GR3018O000 SN 300004630
Equiv. Linkage, S-Band UP, 60 Hz,w.RoJ 390002928
Equiv. Linkage, S-Band UP, 50 Hz,w.RoJ 390002929
Replacement Gearbox, S-Band Down, 50Hz 390004969
Replacement Gearbox, S-Band Down, 60Hz 390004970
S-Band driving 3AC230/400/440V 50/60Hz 300004350
Complete driving 3AC440V 60Hz S-Band 390005262
Start capacitor, 80uF/250V__FOR MOTORTYP 3S14PD2923050 271168627
Kondensator 8uF/400V (Schutzklasse P2)__for Motor 1Ph/230V/50Hz 3S14pD2923050 390004634
Capacitor 16uF/400V__Ersatzteil f
Capacitor, 12uf/400V__FOR MOTORTYP 3X14PD2523050+4S14PD2923060 271168626
Thermo switch__0×C BIS-3×C ÷FFNEN, 10+/- 4×C SCHLIE•EN 5148185
Heating element,100W,220VAC__100W AC220V 50HZ 5379544
Toothed wheel HTD-5M/30-0 1.4301__FOR S-BAND 300004854
Toothed belt CXP HTD 665-5M-25__F.S-BAND-50HZ, CONTI SYNCHROFORCE 300004859
Toothed belt CXP HTD 710-5M-25__F.S-BAND-60HZ, CONTI SYNCHROFORCE 300004860
Toothed wheel HTD-5M/93-2 1.4301__FOR S-BAND 60HZ, WITH TWO FLANGED 300004856
WHEEL
Pulsor 300004129
Shaft seal__GR3018 271168656
Shaft seal__GR3018 271168657
V-Seal (B+S)__GR3018 271168660
O-Ring 274x3__GR3018 271168659
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Round sealing__GR3018 271168661

RF-Sealing (Altoflex)__GR3017 271168650
Grub screw__GR3018 271168663
Sound sensor__GR3018 271168664
Sound sensor, X-Band__OHB 900, MIT STECKER 300005832
AS05-P.-M.AMPL.S-BAND 2871647
FUSE LINK__2AT/440V/6,3X32MM 300004620
FUSE LINK__10AT/440V/6,3X32MM 300004621
FUSE LINK__6,3AT/440V/6,3X32 300004349
FUSE LINK 300003943
Fuse link,T2A,5x20 5071042
Fuse link,T0,16A,5x20 271250056
WAVEGUIDE FLEX, TR UP, S-BAND 390002786
WAVEGUIDE, S-BAND DOWN 2770924
TRANSFORMER 1600 VA with housing__IN AC 115 V, OUT AC 230 V / 1,6 KVA 300004151
Repair kit, HeliCoil plus__HELICOILE AND TOOLS 300006146
X-Band Transceiver NG3040

X-Band Transceiver 12,5kW 390005429
X-Band Transceiver 25kW 390005430
TCU__NG3028G221 390005129
AS10- POWER SUPPLY 2859950
PULSEMODULATOR 390004915
RINGKERN-TRANSFORMATOR 5040580
TESTOSZILLATOR X-BAND 2772328
HS05-TRANSMITTER POWER SWITCH 2869024
TRANSFORMER 2971024
Set of cables,X-Band Transceiver 390005446
X-Band, HF-Unit 390005481
MAGNETRON 5227616
MAGNETRON 5227615
Door Switch 300003634
FERRITE SLEEVE 5049360
TIE WRAP 5361362
Fuse link,T0,16A,5x20 271250056
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S-Band Transceiver NG3041

S-Band Transceiver, 30kW 390005451
Waveguide, Transceiver, S-Band 390005453
S-Band Receiver If-Amplifier 390003332
TEST OSCILLATOR S-BAND 300004096
Cable set, Transceiver, S-Band 390005532
MAGNETRON M1302L 5227611
S-Band Limiter with cable 390005819
RINGKERN-TRANSFORMATOR 5040581
TCU__NG3028G221 390005129
AS10- POWER SUPPLY 2859950
HS05-TRANSMITTER POWER SWITCH 2869024
PULSEMODULATOR 390004915
Door Switch__10 A, 250 V AC 300003634
Fuse link,T0,16A,5x20 271250056
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Gearboxes and Transceivers 8 Technical Data
Technical Manual 8.1 Conformity to Standards, Environmental Conditions
8 Technical Data
8.1 Conformity to Standards, Environmental Conditions
The Gearboxes and Scanners comply with DIN EN 60945 (Maritime navigation and radiocommunication
equipment and systems - General requirements - Methods of testing and required test results).
The system of protection required for the Gearbox by DIN EN 60945 is not valid for internal parts of the
Gearbox.
All components, except of the Scanner and the Gearbox (in Version A including the Transceiver Elec-
tronics) belong to the category "protected from the weather".
The Scanner and the Gearbox (in version A including the Transceiver Electronics) belong to the category
"exposed to the weather".
8.2 Performance
8.2.1 Performance Data of the Antenna Unit’s Motors
Overview of the available motor versions:

Single-phase:

frequency (Hz) rpm rpm
230 50 1 23 23
230 60 1 28 28
Three-phase:

frequency (Hz) rpm low rpm high rpm low rpm high
230 50 3 23 46 23 46
230 60 3 28 56 28 46 1)
400 2) 50 3 23 46 23 46
400 60 3 28 56 28 46 1)
1)
Rotation frequency is reduced from 58 rpm to 46 rpm by a modified Gearbox.
2) also for 440 V/60 Hz
S-Band and X-Band motors may have different turning directions, but the turning direction of the Scanner
is the same. For the power consumption of the motors and additional information such as start or oper-
ating capacitors, see Section 8.4.1.
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8 Technical Data Gearboxes and Transceivers
8.2 Performance Technical Manual
8.2.2 Performance Data of the Scanner
X-Band Scanner
5 foot 8 foot
Antenna Type Slotted antenna Slotted antenna
Horizontal beamwidth 1.5° 0.95°
Vertical beamwidth 23° 21°
Side-lobe attenuation within ±10° >29 dB >29 dB
Side-lobe attenuation outside ±10° >35 dB >35 dB
Polarisation Horizontal Horizontal
Antenna gain 28 dB 30 dB
Frequency band 9350...9410 MHz 9350...9410 MHz
Max. permissible peak transmission power 80 kW 80 kW
Diameter of swing circle 1700 mm 2600 mm
Height 160 mm 160 mm
Width 1678 mm 2578 mm
Depth 195 mm 195 mm
Weight 18 kg 22 kg
S-Band Scanner
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 27.3 dB
Frequency band 3020...3070 MHz
Max. permissible peak transmission power 80 kW
Diameter of swing circle 4300 mm
Height 360 mm
Width 4220 mm
Depth 510 mm
Weight 70 kg
8.2.3 Performance Data of Antenna Heating (optional)
The heating consists of two 100 W heating resistors. It is switched on if the temperature inside the
Gearbox is lower than -10°C.
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Technical Manual 8.2 Performance
8.2.4 Performance Data of the Magnetrons
X-Band:
Peak power of Version A: 12.5 / 25 kW
Peak power of Version B: 25 kW
Frequency: 9375 MHz, +/-30 MHz
S-Band:
Peak power of Version A: 30 kW
Peak power of Version B: 30 kW
Frequency: 3050 MHz +/-10 MHz
8.2.5 Performance Data of the Receiver / HF-Unit
X-Band:
Frequency: 9.32...9.50 GHz
Noise figure: 3.5dB
S-Band:
Frequency: 3.02...3.08 GHz
Noise figure: 3.0dB
8.2.6 Performance Data of the IF Amplifiers NG3028G022/G080 / HF-Unit
IF frequency: 60 MHz
IF bandwidth: 20 MHz / 5 MHz switchable
STC: 65 dB (max.) log decay
8.2.7 Performance Data of the Modulator NG3028G203 / NG3028G206 / NG3028G207
X/S-Band:
Pulse length min.: 80 ns
Pulse length max.: 1000 ns
PRF min.: 500 Hz
PRF max.: 2000 Hz
PRF and pulse length are freely adjustable within their operative range.
The mean transmitting power of
- 6.25 W for 12.5 kW magnetron
- 12.5 W for 25 kW magnetron
- 15.0 W for 30 kW magnetron
will not be exceeded if PRF and pulse length have been adjusted to a suitable value.
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8.3 External Interfaces Technical Manual
8.2.8 Performance Data of the Transmitter Control Unit NG3028G201 / NG3028G221
- Microcontroller 80 C 167 with:

- 9 timers
- 16 A/D converters
- CAN controller
- Pulse width modulation
- Watch dog timer
- Interrupt controller
- 2 serial interfaces
- Various parallel ports
- HW CAN Bus controller
- Serial interface RS232 for debugging
- 2K x 8 Bit EEPROM
- At least 3 stored STC curves, 1024 x 10 bit
- Auto/manual STC function
- Auto/manual AFC function
- Sector blanking (at least 4 sectors)
- Tuning functions
- On-line self-check
- Self-check for transmitter and receiver
- Service concept with remote control
- Control of Antenna Unit
8.2.9 Performance Data of the Power Supply Unit NG3028G202
- AC input from the transformer (transformer input: 115 V/230 V (±10%), 50...60 Hz (±5%))
- Voltage supply for the TCU
- Voltage supply for the Modulator
- Voltage supply for the IF amplifier
- Provides the following voltages:
- +/-15 V
- +5 V
- +24 V
8.3 External Interfaces
The Antenna Unit and the Transceiver have no external interfaces.
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Technical Manual 8.4 Power Supply
8.4 Power Supply
8.4.1 Motors
X-Band
Nom.
Mains rpm Start Operating
current Power/W Motor
supply (nom.) capacitor capacitor
/A
1-ph/230 V 12 µF/ Asynchronous motor
0.8 70 1430 -
50 Hz 400 V (3X14PD2523050)
1-ph/230 V 10 µF/ Asynchronous motor
0.8 70 1730 -
60 Hz 400 V (4X14PD2523060)
1.15/0.55 180/70 - -
50 Hz 1450 (5X32/4PD2523050)
1.05/0.52 180/70 - -
60 Hz 1750 (6X32/4PD2523060)
50 Hz 1) 0.65/0.32 180/70 - -
1450 (7X32/4PD2540050)
0.60/0.30 180/70 - -
60 Hz 1750 (8X32/4PD2540060)
1)
S-Band
Nom.
Mains rpm Start Operating
current/ Power/W Motor
supply (sync.) capacitor capacitor
A
1-ph/230 V 80 µF/ 16 µF/ Asynchronous motor
5.5 900 1430
50 Hz 250 V 400 V (3S14PD2923050)
1-ph/230 V 60 µF/ 12 µF/ Asynchronous motor
5.5 900 1730
60 Hz 250 V 400 V (4S14PD2923060)
4.2/3.2 1000/750 - -
50 Hz 1450 (5S32/4PD2923050)
3.8/3.1 1000/750 - -
60 Hz 1760 (6S32/4PD2923060)
50 Hz 1) 2.4/1.9 1000/750 - -
1450 (7S32/4PD2940050)
2.2/1.75 1000/750 - -
60 Hz 1760 (8S32/4PD2940060)
1)
8.4.2 Transceiver Electronics Unit (Versions A and B)
The maximum power consumption of the Transceiver Unit (not including the motor) is 140 VA.
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8.5 Dimensions and Weights Technical Manual
8.5 Dimensions and Weights
For dimensions and weights, see the technical drawings. The drawings are shown in Section 11.
8.6 Compass Safe Distances
Standard Steering Standard Steering

compass compass compass reduced compass reduced
NG3028/NG3040 1.60 m 0.95 m 1.00 m 0.60 m
X-Band Transceiver
NG3029/NG3041 2.60 m 1.70 m 1.60 m 1.05 m
S-Band Transceiver
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Gearboxes and Transceivers 9 System Faults
Technical Manual
9 System Faults
For the list of fault messages/codes, see the technical manual of the Display Electronics Unit.
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9 System Faults Gearboxes and Transceivers
Technical Manual
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Gearboxes and Transceivers 10 Cabling Documents
Technical Manual
10 Cabling Documents
Title Page
X - B a n d , I n t e r c o n n e c t i o n Tr a n s c e i v e r Ve r s i o n A a n d B , 1 / 1 155
X - B a n d , Tr a n s c e i v e r Ve r s i o n A , g e a r b o x c a b l i n g , 1 / 4 156
X - B a n d , Tr a n s c e i v e r Ve r s i o n A , g e a r b o x c a b l i n g , c o m b i n e d H M a n d A z i m . P u l s e r , 1 a / 4 157
X - B a n d , Tr a n s c e i v e r Ve r s i o n A , r e v. g e a r b o x c a b l i n g , c o m b . H M a n d A z i m . P u l s e r , 1 b / 4 158
X - B a n d , Tr a n s c e i v e r Ve r s i o n B , g e a r b o x c a b l i n g , 2 / 4 159
X - B a n d , Tr a n s c e i v e r Ve r s i o n B , g e a r b o x c a b l i n g , c o m b i n e d H M a n d A z i m . P u l s e r , 2 a / 4 160
X - B a n d , Tr a n s c e i v e r Ve r s i o n B , r e v. g e a r b o x c a b l i n g , c o m b . H M a n d A z i m . P u l s e r , 2 b / 4 161
X - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , M o t o r a n d H e a t i n g c a b l i n g , 3 / 4 162
X - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , M o t o r w i t h T h e r m o s w i t c h a n d H e a t i n g c a b l i n g , 3 a / 4 163
X - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , 1 1 5 V Tr a n s f o r m e r , 4 / 4 164
X - B a n d , Tr a n s c e i v e r Ve r s i o n B , c a b l i n g I n t e r c o n n e c t i o n B o a r d , b u l k h e a d h o u s i n g , 1 / 1 165
S - B a n d , I n t e r c o n n e c t i o n Tr a n s c e i v e r , Ve r s i o n A a n d B , 1 / 1 166
S - B a n d , Tr a n s c e i v e r Ve r s i o n A w i t h S t a r t U n i t 2 , g e a r b o x c a b l i n g , 1 / 7 167
S - B a n d , Tr a n s c e i v e r Ve r s i o n A w i t h S t a r t U n i t 2 , r e v i s e d g e a r b o x c a b l i n g , 1 a / 7 168
S - B a n d , Tr a n s c e i v e r Ve r s i o n B w i t h S t a r t U n i t 2 , g e a r b o x c a b l i n g , 2 / 7 169
S - B a n d , Tr a n s c e i v e r Ve r s i o n B w i t h S t a r t U n i t 2 , g e a r b o x c a b l i n g , 2 a / 7 170
S - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , M o t o r a n d S t a r t U n i t 2 c a b l i n g , 3 / 7 171
S - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , M o t o r w i t h T h e r m o s w i t c h a n d S t a r t U n i t 2 c a b l i n g , 3 a / 7 172
S - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , M o t o r , H e a t i n g a n d S t a r t U n i t 1 c a b l i n g , 6 / 7 173
S - B a n d , Tr a n s c e i v e r Ve r s i o n A a n d B , 1 1 5 V Tr a n s f o r m e r c a b l i n g , 7 / 7 174
S - B a n d , Tr a n s c e i v e r Ve r s i o n B , C o n n e c t i o n B o a r d i n b u l k h e a d h o u s i n g , 1 / 1 175
X - B a n d , Tr a n s c e i v e r Ve r s i o n B , N e w P e r f o r m a n c e S t a n d a r d s , 1 / 1 176
S - B a n d , Tr a n s c e i v e r Ve r s i o n B , N e w p e r f o r m a n c e S t a n d a r d s , 1 / 1 177
X - B a n d , Tr a n s c e i v e r ( A ) , G e a r B o x C a b l i n g , N e w p e r f o r m a n c e S t a n d a r d s , 1 / 4 178
X - B a n d , Tr a n s c e i v e r ( B ) , G e a r B o x C a b l i n g , N e w p e r f o r m a n c e S t a n d a r d s , 2 / 4 179
X - B a n d , Tr a n s c e i v e r , M o t o r a n d H e a t i n g C a b l i n g , N e w p e r f o r m a n c e S t a n d a r d s , 3 / 4 180
X - B a n d , Tr a n s c e i v e r , Tr a n s f o r m e r , N e w p e r f o r m a n c e S t a n d a r d s , 4 / 4 181
See the Technical Manual of the Display Electronics Unit for cabling documents of the complete Radar
System.
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10 Cabling Documents Gearboxes and Transceivers
Technical Manual
Grounding
All components of the radar system have contacts such as bolts or terminals for grounding. Grounding is
important for EMC purposes as well as for protecting people’s lives.
Both purposes are covered by the standard grounding of the system’s housings to the ship’s metallic
structure (bolted or welded). Regardless of the type of ship’s grounding (e.g. star pattern or ground plane
pattern), no potential difference should be measurable between two different ground connectors. Potential
differences cause compensation currents on the cable shields. If the ship has no metallic structure, all
conductively connected metallic parts form an artificial ground.
All ground connections should be as short as possible. If possible, different units should be connected to
individual ground connectors. Whenever possible, metallic housings should be screwed or welded directly
to the ship’s metallic structure. If a safe grounding contact is not ensured, additional conductors are
necessary. Furthermore, all ground connections should have a low RF-impedance, and should be
resistant against vibration and corrosion. Grounding conductors on an open-air deck must be made of
corrosion-protected steel, and inside the ship they must be made of copper.
The grounding should be done in such a way that the connection can be inspected in a convenient
manner.
EMC Purposes
The shields of all cables must be connected at both ends if no other instructions are given.
CAUTION
The screen of the coax cables must be connected to the
cable glands or cable entries of the housings AND to the
appropriate terminals. If the screen is connected to the
terminals only, the signals might be disturbed.
See Figure 3-2 on page 27.
Protective Ground
All removable metallic parts of the housings are grounded by means of separate, flexible cables to the
main structure of the housing. It is important to connect this ground-cable after parts have been
dismounted or exchanged.
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ztr1_407.pdf
Fig. 10-1 X-Band, Interconnection Transceiver Version A and B, 1/1
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Technical Manual
mains supply cable must be connected
to supply the transceiver electronics.
If a 3-ph motor is used, a separate
Only for 1-ph 115 V and 230 V.
ztr1_404.pdf
Fig. 10-2 X-Band, Transceiver Version A, gearbox cabling, 1/4

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ztr1_404a.pdf Fig. 10-3 X-Band, Transceiver Version A, gearbox cabling, combined HM and Azim. Pulser, 1a/4
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Fig. 10-4 X-Band, Transceiver Version A, rev. gearbox cabling, comb. HM and Azim. Pulser, 1b/4
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ztr1_405.pdf
Fig. 10-5 X-Band, Transceiver Version B, gearbox cabling, 2/4
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ztr1_405a.pdf
Fig. 10-6 X-Band, Transceiver Version B, gearbox cabling, combined HM and Azim. Pulser, 2a/4
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Fig. 10-7 X-Band, Transceiver Version B, rev. gearbox cabling, comb. HM and Azim. Pulser, 2b/4
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ztr1_406.pdf
Fig. 10-8 X-Band, Transceiver Version A and B, Motor and Heating cabling, 3/4
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Fig. 10-9 X-Band, Transceiver Version A and B, Motor with Thermoswitch and Heating cabling, 3a/4
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ztr1_400.pdf
Fig. 10-10 X-Band, Transceiver Version A and B, 115 V Transformer, 4/4

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ztr1_408.pdf
Fig. 10-11 X-Band, Transceiver Version B, cabling Interconnection Board, bulkhead housing, 1/1
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ztr1_415.pdf
Fig. 10-12 S-Band, Interconnection Transceiver, Version A and B, 1/1

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Technical Manual
mains supply cable must be connected
to supply the transceiver electronics.
If a 3-ph motor is used, a separate
Only for 1-ph 115 V and 230 V.
ztr1_409.pdf
Fig. 10-13 S-Band, Transceiver Version A with Start Unit 2, gearbox cabling, 1/7
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Fig. 10-14 S-Band, Transceiver Version A with Start Unit 2, revised gearbox cabling, 1a/7
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ztr1_410.pdf
Fig. 10-15 S-Band, Transceiver Version B with Start Unit 2, gearbox cabling, 2/7
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Fig. 10-16 S-Band, Transceiver Version B with Start Unit 2, gearbox cabling, 2a/7
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Fig. 10-17 S-Band, Transceiver Version A and B, Motor and Start Unit 2 cabling, 3/7
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Technical Manual
Fig. 10-18 S-Band, Transceiver Version A and B, Motor with Thermoswitch and
Start Unit 2 cabling, 3a/7
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Fig. 10-19 S-Band, Transceiver Version A and B, Motor, Heating and Start Unit 1 cabling, 6/7
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Fig. 10-20 S-Band, Transceiver Version A and B, 115 V Transformer cabling, 7/7
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Fig. 10-21 S-Band, Transceiver Version B, Connection Board in bulkhead housing, 1/1
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Fig. 10-22 X-Band, Transceiver Version B, New Performance Standards, 1/1
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Fig. 10-23 S-Band, Transceiver Version B, New performance Standards, 1/1
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Fig. 10-24 X-Band, Transceiver (A), Gear Box Cabling, New performance Standards, 1/4
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Fig. 10-25 X-Band, Transceiver (B), Gear Box Cabling, New performance Standards, 2/4
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Fig. 10-26 X-Band, Transceiver, Motor and Heating Cabling, New performance Standards, 3/4
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Fig. 10-27 X-Band, Transceiver, Transformer, New performance Standards, 4/4
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11 Outline Drawings
Title Page
X-Band Antenna Unit, GR3017O000 MB 204
S-Band Antenna Unit, GR3018O000 MB 205
Antenna Unit Mounting Flange S-Band, GR3013T001 206
Antenna Unit Mounting Flange X-Band, GR3004T113 207
X - B a n d Tr a n s m i t t e r , B u l k h e a d , N G 3 0 2 8 O 0 0 0 M B 208
S - B a n d Tr a n s m i t t e r , B u l k h e a d , N G 3 0 2 9 O 0 0 0 M B 209
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1 2 3 4 5 6 7 8
204
d 191,00
A A
100,00
Schlitzstrahler Drehkreisdurchmesser
Slotted waveguide Swing circle
d
Fig. 11-1
5 ft 1689
11 Outline Drawings
8 ft 2585
(119,00)
548,6
429,6
B B
Gewicht/Weight:
300,00
5ft Strahler 8ft Strahler
scanner scanner
160,00
125 ohne / without
Transmitter 54 kg 58 kg
475,00
245 mit / with 60 kg 64 kg
34,5
405 Transmitter
C C
Z Z 1:5 2) Sicherheitsschalter, nur für Motor
Ansicht ohne Antenne Safety switch, only for motor
Without scanner 1) für Mastplatte GR 3004 T 113
is M24x1,5 for Top-Plate
hkre le Kabeleinfeinführung Mitte Mast
140,00
Dre g circ
n Stuffing tube Mast center
Swi
X-Band Antenna Unit, GR3017O000 MB

M12
D D
Antenne ist zugelassen nach IEC 945
M6 Die Aufstellung ist so zu wählen, dass durch

120,00 1)
245
Windanströmung oder Schiffsvibration keine
EIN/AUS unzulässigen Bekastungen auftreten

ON/OFF 2)
Hohlleiter Ausgang 100

E
Waveguide outlet
200 1)
Allg. - Toleranzen/ Oberfläche/ Maßstab / Scale: 1:10 2766364

Gen. tolerances Treatment
Werkstoff / Material:
ISO 2768-m
Datum/Date Name
Bearb. 10.02.1999 Guenther
Gepr. 18.06.1999 Haertel
X-BAND-ANTENNENEINHEIT
Norm. ANTENNA-UNIT
F MST 22
C 600000000458 Reg. Blatt/Sheet
02.11.04
B - 01.12.99 Rei 1
SAM Electronics GR 3017 O 000 MB
A - 22.06.99 Gue 1 Bl.
1 2 3 4 Ind. Änderung Datum Name
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Fig. 11-2 S-Band Antenna Unit, GR3018O000 MB

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Fig. 11-3 Antenna Unit Mounting Flange S-Band, GR3013T001

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Fig. 11-4 Antenna Unit Mounting Flange X-Band, GR3004T113

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Fig. 11-5 X-Band Transmitter, Bulkhead, NG3028O000 MB

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Fig. 11-6 S-Band Transmitter, Bulkhead, NG3029O000 MB

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Notes
Space for your notes:
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RADAR 1100 Series: Technical Manual

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RADAR 1100 Series: Technical Manual

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Technical Manual

RADAR 1100 Series

Including Installation Instructions

Item No.: ED3051G442 Revision: 04 (2008-07) Order No.: 390001632

SAM Electronics GmbH

6.2 List of Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7.9 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

8 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

9 System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

10 Cabling Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

11 Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Fig. 1-1 Version label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

This Technical Manual is the technical reference manual for:

1.1 Software Releases

1.2 Hardware Versions

Hardware for advanced performance standards:

From software version 5.0.0. on, the MULTIPILOT/RADARPILOT fulfils

Unit/Parts System Documentation

Rev., marked by "X"

Order No. Item No. of Serial No.

Fig. 1-1 Version label

Item No. of the pcb itself, Print version

Fig. 1-2 Pcb labelling

1.3 General Recommendations for Installation, Maintenance and Repair Work

1.4 Safety Warnings

If a synchro or a stepper is connected to the Analog Inter-

Capacitors and tubes can store dangerous voltages for

The man aloft switch in the Gearbox switches only the

1.5 Dangerous High Frequency Radiation

During normal operation, the transmitter is automatically

Radius of the Radiation Danger Zone

1.6 Safety Switches

1.6.1 Man Aloft Switch

The man aloft switch is situated under the Gearbox. If it is switched to

1.6.2 HV Supply Switch (Interlock)

The HV supply switch in the Transceiver switches off the high

pulled out to supply power to the RF electronics.

HV supply switches (different versions)

Fig. 2-1 System overview

RADARPILOT 1102 / ARPA - 2A8X

Options: Antenna Size:

Plotting Aid: 2 = 25 kW X-Band

2.2 Antenna Unit GR3017 / GR3018 / GR3040 / GR3041

Fig. 2-3 S-Band Gearbox GR3018/GR3041, X-Band Gearbox GR3017/GR3040

2.2.2 Scanner GR3004 / GR3021 / GR3009 / GR3021

2.3 Transceiver Electronics Units NG3028 / NG3029 / NG3040 / NG3041

The Transceiver is available in the following versions:

2.3.2 Transceiver Versions

The Transceiver is available with various transmitter performances (nominal power):

2.3.3 Components of the Transceiver

The Transceiver electronics contains the following parts:

2.5 Compatibility with SAM Electronics Radar / NACOS 1) equipment

1) Navigation and Command System

3.1 General Recommendations

Fig. 3-1 Preparation of the cable endings

Fig. 3-2 Cable glands with grounding inserts

Metal clamp inside Installation cables

35+5 Screen braid laid back over outer sheathing;

Metal clamp outside

Fig. 3-3 Cable inlet consisting of a hole with brackets

3.1.1.1 Maximum Cable Length

Coaxial S-Band Cable/Flexible X-Band Waveguide

Coaxial Cable for TVA Signal