Finmeccanica Selex ES Radom650C User manual

Radome_Radom650C_Service M anual_en_2014-06-04
Selex ES GmbH • Gematronik Weather Radar Systems
Table of Contents
04.06.2014
Service Manual
Radom650C
Radome
Translation of the original manual

2 Selex ES GmbH • Gematronik Weather Radar Systems
© Selex ES GmbH
Gematronik Weather Radar Systems
Raiffeisenstraße 10
41470 Neuss
GERMANY
Tel.: +49 - 2137 - 782 - 0
Fax.: +49 - 2137 - 782 - 11
[e-mail]
www.gematronik.com
Release: 04.06.2014
Project: 176NOC

Radom650C Radome
Table of Contents
Selex ES GmbH • Gematronik Weather Radar Systems 3
Table of Contents
1General........................................................................................................................5
1.1 Information about this operating manual.......................................................5
1.2 Conventions used.............................................................................................6
1.2.1 Notes ....................................................................................................6
1.2.2 Special safety instructions ....................................................................7
1.2.3 Frequency bands..................................................................................8
1.3 Manufacturer information ................................................................................9
1.3.1 Limitation of liability...............................................................................9
1.3.2 Warranty terms .....................................................................................9
1.3.3 Customer service................................................................................10
1.3.4 Contact data........................................................................................10
1.4 Spare parts......................................................................................................11
2Safety ........................................................................................................................13
2.1 Responsibility of the owner...........................................................................13
2.2 Personnel requirements.................................................................................15
2.2.1 Qualification........................................................................................15
2.2.2 Unauthorized persons.........................................................................18
2.2.3 Instruction ...........................................................................................18
2.3 Intended Use ...................................................................................................19
2.4 Personal protective equipment .....................................................................20
2.5 Special dangers ..............................................................................................22
2.6 Safety devices.................................................................................................24
2.7 Behavior in the event of danger or accident................................................25
2.8 Environmental protection ..............................................................................26
2.9 Signs................................................................................................................27
2.9.1 Warnings.............................................................................................28
2.9.2 Fire safety signs..................................................................................30
2.9.3 Mandatory signs..................................................................................30
2.10 Spare parts......................................................Fehler! Textmarke nicht definiert.
3Structure and function.............................................................................................31
3.1 Overview..........................................................................................................31
3.2 Brief Description.............................................................................................32
4Technical data..........................................................................................................33
4.1 General information........................................................................................33
4.2 Operating conditions......................................................................................34
4.3 Type plate........................................................................................................34
5Transport, packaging, and storage........................................................................35
6Installation and commissioning .............................................................................37

Radom650C Radome
Table of Contents
4 Selex ES GmbH • Gematronik Weather Radar Systems
7Operation ..................................................................................................................39
8Configuration............................................................................................................41
9Faults.........................................................................................................................42
10 Service.......................................................................................................................43
10.1 Safety ...............................................................................................................43
10.2 Logging maintenance tasks...........................................................................45
10.3 Service schedule.............................................................................................46
10.4 Measures prior to service work .....................................................................48
10.5 Measures while performing maintenance.....................................................49
10.6 Accessibility for performing maintenance....................................................50
10.6.1 Entering the radome............................................................................50
10.6.2 Positioning the reflector.......................................................................51
10.6.3 Reaching roof components .................................................................52
10.6.4 Reaching panels on the inside of the radome.....................................53
10.6.5 Reaching panels on the outside of the radome...................................54
10.7 Service tasks ...................................................................................................55
10.7.1 Checking the obstruction light.............................................................55
10.7.1.1 Performing a visual inspection ..............................................56
10.7.1.2 Replacing the obstruction light..............................................56
10.7.2 Checking the panel surface.................................................................58
10.7.2.1 Performing a visual inspection ..............................................60
10.7.2.2 Sequence of repair steps ......................................................60
10.7.2.3 Panel replacement ................................................................61
10.7.2.4 Panel repairs.........................................................................67
10.7.2.5 Restoring the surface coating................................................72
10.7.2.6 Panel cleaning.......................................................................
73
10.7.3 Checking the radome tightness...........................................................74
10.7.4 Re-tighten threaded unions on the panel............................................76
10.7.5 Check turnbuckles of the guy ropes for firm seat................................80
10.8 Steps after maintenance is complete............................................................82
11 Disassembly and disposal.......................................................................................85
12 Appendix...................................................................................................................87
12.1 Panel arrangement..........................................................................................87
12.2 Tightening torques..........................................................................................88
13 Index..........................................................................................................................89

Radom650C Radome
General
Selex ES GmbH • Gematronik Weather Radar Systems 5
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1 General
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1.1 Information about this operating manual
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This manual enables safe and efficient handling of the radar system. The manual is a
component of the system and must be kept in the vicinity of the radar system where it is
available to specialized personnel at all times.
Personnel must have carefully read and understood this manual prior to starting any task.
The basic prerequisite for safe work is compliance with all the safety instructions and
handling instructions specified in this manual.
In addition, the local occupational health and safety regulations, accident prevention
regulations and general safety regulations for the radar system’s area of implementation
also apply.
The illustrations in this manual are provided for purpose of basic understanding and can
deviate from the actual version.
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Higher-level and supplemental manuals
This subsystem can be combined with different components Supplemental dangers
emanate from these components, which cannot be considered in this manual.
Consequently this manual must only be given to others in combination with the operating
manual for the radar system. In the radar system operating manual the system is
considered in its entirety and the knowledge of safe handling is imparted.
The manuals for the other subsystems are additional sources of information.
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Customer-provided components
This manual refers exclusively to the subsystems and assemblies manufactured by
SELEX-Gematronik. This manual does not describe any customer-provided components
that have been manufactured by the client (from the SELEX-Gematronik perspective) or
that have been supplied by third parties on behalf of the client.
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Radom650C Radome
General
6 Selex ES GmbH • Gematronik Weather Radar Systems
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1.2 Conventions used
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1.2.1 Notes
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Warnings
Warnings are indicated by symbols in this manual. The warnings are introduced by signal
words that express the scope of the hazard.
The warnings must be strictly complied with, you must act prudently to prevent accidents,
personal injury, and material damage.
DANGER!
… indicates an imminent dangerous situation that can result in death or
serious injury if it is not avoided.
WARNING!
… indicates a possible dangerous situation that can result in death or
serious injury if it is not avoided.
CAUTION!
… indicates a possible dangerous situation that can result in minor injury if
it is not avoided.
CAUTION!
… indicates a possible dangerous situation that can result in material
damage if it is not avoided.
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Tips and recommendations
Tips and recommendations for handling the system are indicated in this manual by the
symbol "i" and are emphasized graphically.
NOTE!
... indicates useful tips and recommendations as well as information for
efficient and trouble-free operation.
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Radom650C Radome
General
Selex ES GmbH • Gematronik Weather Radar Systems 7
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1.2.2 Special safety instructions
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DANGER!
Life-threatening danger due to electric shock!
… indicates life-threatening situations due to electrical current. If the safety
instructions are not heeded there is a hazard of serious injury or death.
The work that must be executed should only be performed by a qualified
electrician.
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DANGER!
Life-threatening danger due to ionizing radiation!
… indicates life-threatening situations due to ionizing radiation. If the safety
instructions are not heeded there is a hazard of serious injury or death.
The work that must be executed should only be performed by a qualified
electrician.
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DANGER!
Danger of injury due to non-ionizing, electromagnetic radiation!
… indicates hazardous situations due to non-ionizing electromagnetic
radiation. There is danger of injury if the safety instructions are not
heeded.
The work that must be executed should only be performed by a qualified
electrician.
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DANGER!
Life-threatening danger due to strong magnets!
… indicates life-threatening situations due to strong magnets. If the safety
instructions are not heeded there is a hazard of serious injury or death.
The work that must be executed should only be performed by a qualified
electrician.
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CAUTION!
Electrostatic-sensitive components!
… indicates components containing parts that are electrostatic sensitive.
These parts can be destroyed if not handled properly.
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Radom650C Radome
General
8 Selex ES GmbH • Gematronik Weather Radar Systems
1.2.3 Frequency bands
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The nomenclature used in this manual for specification of frequency bands is based on
the IEEE Standard 521-2002 (Standard Letter Designations for Radar-Frequency Bands).
NOTE!
For additional information, see the section "Appendix  Frequency bands"
in accordance with IEEE Standard 521-2002.
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Radom650C Radome
General
Selex ES GmbH • Gematronik Weather Radar Systems 9
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1.3 Manufacturer information
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1.3.1 Limitation of liability
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All information and instructions in this operating manual have been provided under due
consideration of applicable guidelines, the current state of technology, as well as our
many years of experience.
The manufacturer assumes no liability for damages due to:
Failure to follow the instructions in the manual
Non-intended use
Deployment of untrained personnel
Unauthorized conversions
Technical changes
Use of non-approved spare parts
The actual scope of delivery can vary from the explanations and graphic representations
provided in this manual in the case of special versions, if supplemental order options are
desired, or on the basis of the latest technical changes.
In all other respects the agreed obligations in the delivery contract, the general terms and
conditions, as well as delivery conditions of the manufacturer, and the statutory
regulations valid at the time the contract was concluded, apply.
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1.3.2 Warranty terms
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For our warranty terms, please refer to the contract documents.
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The prerequisite for acknowledging a guarantee case is compliance with all maintenance
tasks in accordance with the prescribed maintenance intervals.
During the guarantee period maintenance tasks must be recorded in writing. These
maintenance logs must always be submitted in order for a guarantee case to be
acknowledged. Maintenance that is not executed or not correctly executed can result in
exclusion from the guarantee.
NOTE!
See the chapter, "Safety  Logging maintenance tasks" for additional
information.
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Radom650C Radome
General
10 Selex ES GmbH • Gematronik Weather Radar Systems
1.3.3 Customer service
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Our customer service organization is available for information on the product, product
documentation and ordering spare parts.
Our employees are always interested in new information and experiences associated with
the application, which could prove valuable in improving our products, and in improving
the associated product documentation.
See the section "Contact data" for contact information.
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1.3.4 Contact data
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Technical enquiries concerning the product are handled at SELEX-Gematronik via the
"After Sales Service" organization. For prompt handling of your enquiry use the following
email address:
[email protected]
All requests concerning the product documentation should be directed to our
Documentation Department (preferably in English):
[email protected]
For additional contact data, see page 2.
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Radom650C Radome
General
Selex ES GmbH • Gematronik Weather Radar Systems 11
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1.4 Spare parts
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Only original spare parts from SELEX-Gematronik offer you protection and safety for
operating your weather radar system.
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WARNING!
Injury hazard if the wrong spare parts are used!
Incorrect or defective spare parts can cause damage, malfunction, or total
failure; they can also impair safety.
Therefore:
– Only use manufacturer's original spare parts.
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CAUTION!
Invalidation of the Declaration of Conformity in accordance with the
Machinery Directive!
Replacement of a component with a spare part that is not specified by
SELEX-Gematronik eventually results in a significant change on the
weather radar system.
The party responsible for the replacement of the spare part must check
whether a significant change is present. If a significant change is present
the existing Declaration of Conformity will be invalidated in accordance with
Machinery Directive 2006/42/EC. The party that executed the significant
change becomes the manufacturer and must execute a new conformity
evaluation procedure for the entire weather radar system. The weather
radar system cannot be operated until this procedure is concluded.
Therefore:
– Only use the manufacturer's original spare parts.
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NOTE!
SELEX-Gematronik can repair defective spare parts. We recommend
keeping a stock of components that are susceptible to wear. This will
enable you to install a spare part when needed, and in the meantime send
the defective part to SELEX-Gematronik for repair.
Repair of spare parts offers cost savings compared to the purchase price of
new parts. Consequently always handle and store defective spare parts
with care; handle them as you would new parts until they are sent to
SELEX-Gematronik.
Purchase spare parts from authorized dealers or direct from the manufacturer. See page
2 for manufacturer's address.
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Radom650C Radome
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12 Selex ES GmbH • Gematronik Weather Radar Systems
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Radom650C Radome
Safety
Selex ES GmbH • Gematronik Weather Radar Systems 13
2 Safety
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This section provides an overview of all the important safety aspects for optimal protection
of personnel, as well as for safe and trouble-free operation.
Significant hazards can occur if the handling instructions and safety instructions in this
manual are not complied with.
2.1 Responsibility of the owner
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The system is used in commercial applications. Consequently, the owner of the system is
subject to legal occupational health and safety obligations.
NOTE!
The owner is a natural or legal person who operates the system himself for
commercial purposes or provides it to a third party for use/application and
during operation, and who during operation bears the legal product
responsibility for protection of the user, personnel or third parties.
In addition to the industrial safety instructions in this operating manual, generally valid
safety and accident protection guidelines, and environmental protection guidelines must
be followed and complied with for the area of implementation.
In this regard:
The owner must inform himself of applicable occupational health and safety
regulations, and in a hazard analysis identify other hazards that may exist at the
installation site due to the special work conditions. The owner must convert this
information relative to hazards into operating instructions for operation of the system.
The owner must ensure during the entire period of system implementation that the
operating instructions created by the owner correspond to the current state of
legislation, and if necessary the owner must adapt these operating instructions.
The owner must appoint a person who is responsible for safe operation of the system
and coordination of all tasks on the machine.
The owner must clearly regulate and specify responsibilities for installation, operation,
maintenance, and cleaning.
The owner must ensure that the machine is only operated within the framework of the
intended operating conditions and ambient conditions.
The owner must ensure that the machine is only operated with the attached
protective devices.
The owner must ensure that all employees who handle the system have read and
understood the manual. In addition, the owner must train personnel and inform
personnel of the hazards at regular intervals.
The owner must provide the required protective equipment for personnel.
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Radom650C Radome
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14 Selex ES GmbH • Gematronik Weather Radar Systems
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Key transfer system
Prerequisite for safe operation of the radar system with the key transfer system:
At the final inspection of the radar system two keys each with key number 038 and
200 are provided for the key transfer system.
The operator/owner is obligated to ensure that in normal operation only one key
remains with the radar system. This is the only way that safe operation is possible.
Exception: If there is a total shutdown of the radar system (main switch is secured by
lock), which is equipped with more than one key switch, it is permissible to have
multiple keys 200 on the radar site
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Faultless technical condition
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Moreover the customer is responsible for ensuring that the system is always in faultless
technical condition; consequently the following applies:
The customer must ensure that the service intervals described in this service manual
are observed.
During the guarantee period the customer must log all maintenance tasks, including
the actual operating times and the newly determined operating parameters. If there is
guarantee claim the maintenance log will be reviewed to verify that maintenance has
been properly performed.
The customer must have all safety devices inspected regularly for function and for
completeness.
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Radom650C Radome
Safety
Selex ES GmbH • Gematronik Weather Radar Systems 15
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2.2 Personnel requirements
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WARNING!
Danger due to insufficiently qualified personnel!
Inadequately qualified personnel cannot assess the risks associated with
handling the system and expose themselves and others to the danger of
fatal or severe injuries.
Therefore:
– Only have activities performed by qualified personnel.
– Keep inadequately qualified personnel out of the work area.
– Persons whose capacity to react is impaired, e.g. through drugs, alcohol,
or medication are not approved as personnel.
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WARNING!
Danger due to unauthorized access!
Unauthorized persons cannot assess the hazards in the work area and can
harm themselves and others.
Therefore:
– Keep unauthorized persons away from the work area.
– If in doubt, speak to these persons and instruct them to leave the work
area.
– Interrupt tasks as long as unauthorized persons are in the work area.
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Only persons from whom it can be expected that they reliably execute their work are
considered as personnel. Persons whose capability to react is impaired, for instance
through drugs, alcohol, or medication, are not approved.
Comply with age-specific and job-specific regulations that are applicable at the
installation site when selecting personnel.
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2.2.1 Qualification
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This manual is designed for specialized personnel in general.
The precise qualification requirements are oriented to the type of activity. These
requirements are categorized and defined in the qualification profiles below.
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Radar engineer
A radar engineer is a person who due to his specialized training, skills, and
experience, as well as knowledge of the applicable regulations is capable of
executing work on radar systems and electrical equipment and of recognizing and
avoiding possible hazards on his own.

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16 Selex ES GmbH • Gematronik Weather Radar Systems
The radar engineer has at least the technical training of a radar technician and has
the skills and experience necessary to handle radar systems safely.
The radar engineer has been trained by the manufacturer in how to handle the radar
system and has confirmed his participation in this training in writing.
NOTE!
Maintenance training
User training by SELEX-Gematronik is part of the system transfer. In
addition to general radar fundamentals, users are also trained to
handle the weather radar system and are instructed in radar-specific
hazards. The prerequisite for user training is an electrician or
mechanical engineer qualification.
The radar engineer is capable of controlling, calibrating the system, and diagnosing
system faults with the aid of the supplied control and diagnostic software, based on the
supplied hardware and software documentation.
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Electrical engineer
An electrical engineer is a person who due to his specialized training, skills, and
experience, as well as knowledge of the applicable regulations is capable of
executing work on electrical equipment and of recognizing and avoiding possible
hazards on his own. He is familiar with the regionally applicable electrical engineering
safety regulations and accident prevention regulations.
The electrical engineer is especially trained for the particular installation site where he
is active and is familiar with all relevant standards and regulations.
In addition written confirmation of instruction from a radar engineer relative to the
system-specific procedures is required.
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Mechanical engineer
A mechanical engineer is a person who due to his specialized training, skills, and
experience, as well as knowledge of the applicable regulations is capable of
executing tasks on mechanical system components and of recognizing and avoiding
possible hazards on his own. He is familiar with the regionally applicable safety
regulations and accident prevention regulations, that are particularly relevant for the
mechanical system parts.
The mechanical engineer is especially trained for the particular installation site where
he is active and is familiar with all relevant standards and regulations.
In addition written confirmation of instruction from a radar engineer relative to the
system-specific procedures is required.
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Selex ES GmbH • Gematronik Weather Radar Systems 17
Supervisory worker at height
is a person who due to his specialized training, skills, and experience, as well as
knowledge of the applicable regulations is capable of executing and supervising work
at height involving rope access technology.
Due to his training and experience he is also capable of independently recognizing
and avoiding the possible hazards in connection with work at height involving rope
access technology and familiar with all necessary rescue measures.
The supervisory worker at height has successfully completed training in rope access
technology in three stages and can provide proof thereof. He has gained practical
experience of at least 2,400 hours on the rope over a period of at least 24 months
and can provide proof thereof.
The supervisory worker at height has been trained by the radar manufacturer in how
to handle the radar system and has confirmed his participation in this training in
writing. While undergoing training, he has gained the skills and experience necessary
to assess and avoid the risks involved with handling the radar system.
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Worker at height
is a person who due to his specialized training, skills, and experience, as well as
knowledge of the applicable regulations is capable of executing work at height
involving rope access technology.
Due to his training and experience he is also capable of independently recognizing
and avoiding the possible hazards in connection with work at height involving rope
access technology and familiar with the necessary rescue measures.
The worker at height has successfully completed training in rope access technology
in two stages and can provide proof thereof.
The worker at height has been trained by the radar manufacturer in how to handle the
radar system and has confirmed his participation in this training in writing. While
undergoing training, he has gained the skills and experience necessary to assess
and avoid the risks involved with handling the radar system.
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Instructed person
An instructed person is a person who has been instructed by the owner concerning
the tasks assigned to that person and the possible dangers associated with improper
behavior.
The knowledge to use a system, prepared for the normal operation, has been
imparted to an instructed person.
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18 Selex ES GmbH • Gematronik Weather Radar Systems
2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons who do not satisfy the requirements described here
are not aware of the hazards in the work area.
Therefore:
– Keep unauthorized persons away from the work area.
– If in doubt, speak to these persons and instruct them to leave the work
area.
– Interrupt work as long as unauthorized persons are in the work area.
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2.2.3 Instruction
The customer must instruct personnel on a regular basis. Execution of the instruction
provided must be logged for better traceability.
Specify the following information in the log:
Date
Name
Type of instruction
Instruction executed by
Signature
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Selex ES GmbH • Gematronik Weather Radar Systems 19
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2.3 Intended Use
The system has been designed and constructed exclusively for the intended use
described in the operating manual for the overall system.
Every assessment of the safety of the device was conducted based on the technical
specifications provided by the manufacturer.
WARNING!
Danger due to improper servicing and technical modifications!
Servicing the device in an improper manner or introducing unauthorized
technical modifications may affect the device's suitability for the intended
use and lead to dangerous situations.
Therefore:
– The subsystem may only be used in the original configuration within the
overall system that was set up by the manufacturer.
– Service the device only in accordance with the technical specifications
provided by the manufacturer.
– When servicing the device, use only spare parts approved and
considered to be compatible by the manufacturer.
– Strictly comply with all information in this operating manual.
– The customer may only perform the service operations described in this
manual.
– For questions and information on service operations not described
herein, contact the manufacturer.
Claims of any type due to damage arising from non-intended use are excluded.
The customer is responsible for any damage caused by unauthorized modifications of the
devices.
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20 Selex ES GmbH • Gematronik Weather Radar Systems
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2.4 Personal protective equipment
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For some tasks, wearing personal protective equipment is required to minimize health
hazards.
Always wear the protective equipment necessary for the respective task when
working with the device.
Follow the instructions that have been posted in the work area.
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For special tasks wear
Special protective equipment is required when executing special tasks. Separate
reference is made to this equipment in the specific sections. This special protective
equipment is explained below:
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Protective work clothing
is tight-fitting work clothing of low tensile strength with tight-fitting sleeves and no parts
sticking out. It is primarily used to prevent the person wearing it from becoming entangled
in the moving parts of the machine.
Refrain from wearing any rings, chains or other jewelry.
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Hard hat
to protect against falling and flying parts and materials.
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Safety footwear
for protection against heavy falling parts and slipping on slippery substrates.
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Protective gloves
to protect hands from friction, abrasion, puncture wounds, or deeper injuries, as well as
from contact with hot surfaces.
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Safety goggles
protect the eyes from flying parts and splashes of liquid.
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Hearing protection
to provide protection against hearing damage.