KELVIN HUGHES X-band User manual

KELVIN HUGHES X-band 12kW
UPMAST TRANSCEIVER
INSTALLATION INSTRUCTIONS
HBK-2300-3
Issue 2
SITUATIONAL INTELLIGENCE, THE WORLD OVER

X-band 12kW Upmast Magnetron Transceiver
Chapter 1: Contents
HBK-2300-3 Issue 2
Page 2 of 40
Document history
Issue
number
Release date
Details
1
24th March 2016
1st Release
2
15th June 2016
Updates to specifications.
General amendments and changes in formatting.
Cable details changed.
Amendment record
When an amendment is incorporated into this handbook, the details should be recorded below. Any
equipment modifications should also be shown.
Amendment number
Date inserted
(DD-MM-YYYY)
Initials
Equipment
modification number
© Copyright Kelvin Hughes (2016) limited all rights reserved
Printed copies of this document are unmaintained
No parts of this publication may be reproduced, transmitted, transcribed, translated or stored in any
form or by any means without the written permission of Kelvin Hughes Limited
Technical details contained in this publication are subject to change without notice
Where translated, the original English version of this document will remain the definitive document
and should be referred to in any situation of doubt, confusion or conflict
This publication supersedes all previous versions

X-band 12kW Upmast Magnetron Transceiver
Chapter 1: Contents
HBK-2300-3 Issue 2
Page 3 of 40
1 Contents
1Contents ......................................................................................................................................... 3
2Health & Safety............................................................................................................................... 5
3General Notices.............................................................................................................................. 9
3.1 Suggested tools ......................................................................................................................................... 9
3.2 Fitting kit contents ...................................................................................................................................... 9
3.3 Disclaimers .............................................................................................................................................. 10
3.4 Declaration of conformity ......................................................................................................................... 10
4Typical system ............................................................................................................................. 11
5Mechanical installation................................................................................................................ 13
5.1 Location requirements.............................................................................................................................. 13
5.2Transceiver installation ............................................................................................................................ 14
5.3 Antenna installation.................................................................................................................................. 16
5.4 E70352 Power supply .............................................................................................................................. 17
5.5 DIMENSIONS .......................................................................................................................................... 19
5.5.1 Transceiver ..................................................................................................................................... 19
5.5.2 Mounting hole dimensions............................................................................................................... 20
5.5.3 E70352 DC Power Unit ................................................................................................................... 21
5.6 Compass safe distances .......................................................................................................................... 21
6Cabling guidance .........................................................................................................................23
6.1 General advice......................................................................................................................................... 23
6.2 Grounding ................................................................................................................................................ 24
7CONNECTION DETAILS .............................................................................................................. 25
7.1 Transceiver .............................................................................................................................................. 25
7.2 Longer LAN cable .................................................................................................................................... 25
7.3 Power Supply........................................................................................................................................... 26
7.4 Breaker and fuse ratings .......................................................................................................................... 27
8Setting to work .............................................................................................................................29
8.1 Radar scanner initial power on test.......................................................................................................... 29
8.2 Radar checks ........................................................................................................................................... 29
8.3 Check and adjust bearing alignment........................................................................................................ 30
8.4 Troubleshooting ....................................................................................................................................... 31
9Specification.................................................................................................................................33
10 Optional AC/DC power supply ............................................................................................... 35
10.1 Installation ........................................................................................................................................... 35
10.2 Grounding............................................................................................................................................ 35
10.3 Termination.......................................................................................................................................... 36
10.4 Specifications ...................................................................................................................................... 36
10.5 Operation............................................................................................................................................. 36
10.6 Maintenance ........................................................................................................................................ 36
11 Contacting Kelvin Hughes ..................................................................................................... 37

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X-band 12kW Upmast Magnetron Transceiver
Chapter 2: Health & Safety
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2 Health & Safety
When working on Kelvin Hughes Ltd equipment, operators, engineers and agents must work within the health and safety
guidelines noted in this handbook and as issued by their respective employer or as stated by site regulations, shipyard or
vessel owner.
Risk assessments of a working area must be undertaken prior to commencement of any work and must be regularly reviewed.
HAZARDS
The equipment is constructed so that access to high voltages may only be gained after having used a tool, such as a spanner
or screwdriver. Warning labels are prominently displayed both within the equipment and on protective covers.
WARNING: ELECTRICAL HAZARDS
Some equipment does not have safety interlocks fitted.
Lethal single phase AC and DC voltages may be present when units are open and exposed.
Before accessing any internal parts, ALL power sources to the equipment must be fully isolated; this must include the isolation
of any UPS supported supplies to the system.
WARNING: HIGH VOLTAGES
This product contains high voltages.
Do NOT remove any covers or otherwise attempt to access internal components, unless specifically instructed in this
document.
WARNING: SWITCH OFF POWER SUPPLY
Ensure all power supplies are switched OFF before starting to install this product.
Do NOT connect or disconnect the equipment with the power switched ON, unless instructed in this document.
ANTENNA ROTATION WARNING
WARNING: RADAR SCANNER SAFETY
Before rotating the radar scanner, ensure all personnel are clear.
EQUIPMENT ACCESS
NOTICE: ACCESS TO EQUIPMENT
To meet with electrical safety recommendations, all equipment should be situated in a restricted area where access is only
available to authorised personnel.
Persons entering the restricted area should be aware of the dangers that are present when the system is operational which
include rotating equipment, radiation hazards and where applicable, working at heights
RADIATION HAZARDS
RADHAZ WARNINGS
Avoid exposure to the main beam of a stationary radar antenna.
Avoid standing closer than 2 metres from the central front face of the antenna.
Users of cardiac pacemakers should be aware of the possibility that radio frequency transmissions can damage some devices
or cause irregularities in their operation. Anyone using such devices should understand the risks present before exposure.
The radar scanner transmits electromagnetic energy at microwave frequencies which can be harmful, particularly to the eyes.
Do NOT look at the scanner from close range. Ensure personnel are clear of the scanner when it is powered on.
Antenna
Range Within Which the Power Density Exceeds the following:
10W/m2
100W/m2
Rotating
34 cm or less from the radar scanner
A power density level of 100 W/m2does
not occur at any point.

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Chapter 2: Health & Safety
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WORKING ALOFT
CAUTION: SAFETY ALOFT
When working aloft or near any radar scanners, moving or RF radiating equipment, ALL power sources to the platform and
equipment must be fully isolated.
Prior to working aloft, all AC supply breakers supplying power to the system must be switched OFF and locked. Ensure
someone in authority or at ground level knows of your intentions and ensure that suitable clear warnings are in place.
Ensure all means of access aloft are secure and beware of wet or slippery ladder rungs and working areas.
All working at height health & safety requirements and procedures including the inspection and use of personal protective
equipment (PPE) such as approved safety harnesses and gloves, must be adhered to at all times as required by your
employer, site regulations, shipyard and / or vessel.
CAUTION: SAFETY CORDON
When working aloft a safety cordon must be established and managed below the working area(s).
CAUTION: DROP HAZARDS
When working aloft, all tools, Line Replacement Units (LRU’s) and any loose items must be safely stowed or secured so that
they cannot present a drop hazard.
CAUTION: WEATHER HAZARDS
When weather conditions are poor, a full risk assessment must be carried prior to working aloft as defined by an individual’s
employer or shipbourne safety procedures. Poor weather conditions can include but are not restricted to high winds, heavy rain,
snow, ice or if access is required at sea, risk of vessel pitch and roll.
ANTI-STATIC HANDLING
Certain semiconductor devices used in the equipment are liable to damage due to static voltage. Persons removing sub-units
from equipment containing these devices must be earthed by a wrist strap and a resistor at the labelled point provided on/
within the equipment.
Observe the following precautions when handling these devices in their un-terminated state, or sub-units containing these
devices:
Soldering irons used during authorised repair operations must be low voltage types with earthed tips and isolated from the
mains voltage by a double insulated transformer.
Outer clothing worn must be unable to generate static charges.
Printed circuit boards fitted with these devices must be stored and transported in anti-static containers.
Fit new devices in a special antistatic safe handling area.
Fully isolate and mechanically disconnect all sources of AC before attaching ESD protective wrist straps to the various points in
the system.
RoHS STATEMENT
For details on RoHS statements please contact Kelvin Hughes Ltd; contact details can be found in at the end of this handbook.
END OF LIFE DISPOSAL
When the equipment detailed in this handbook has reached the end of its serviceable life, the various parts that
make up the system must be disposed of in accordance with the WEEE Directive.
The Waste Electrical and Electronic Equipment (WEEE) Directive requires the recycling of waste electrical and
electronic equipment. Whilst the WEEE Directive does not apply to some Kelvin Hughes Ltd products, we support
its policy and ask you to be aware of how to dispose of this product.

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Chapter 2: Health & Safety
HBK-2300-3 Issue 2
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GROUNDING/ EARTH POINTS
All parts of the system must be fully and correctly connected to a proven earth point prior to connecting any source of AC or DC
power.
The system must never be switched ON or operated with an earthing point disconnected.
Connection point: The equipment is fitted with a single protective earth connection point which is indicated on the
mechanical installation drawings.
Conductivity tests: During installation and maintenance, the earth connections must be tested for conductivity using
a high current impedance meter such as a Megger or similar.
Wrist Straps: Fully isolate and mechanically disconnect all sources of AC or DC supply before attaching ESD
protective wrist straps to the various points in the system.
WARNING
The system must NOT be operated or have power switched ON with Earth/ Grounding points disconnected.
SERVICING AND REPAIR
Service and equipment repair must only be undertaken by an authorised service agent/ engineer. Un-authorised repair or
servicing of equipment during the warranty period may invalidate the warranty status of the equipment.
LIFTING EQUIPMENT
All health and safety requirements must be checked and observed at all times when lifting any equipment. All appropriate
personal protective equipment (PPE) must be worn.
Where special equipment such as cranes hoists and jigs is required, consideration must be given to the authority to use
such equipment.
During lifting, a safety zone shall be established beneath the lifting area around any cranes or platforms. Safety personnel
must ensure that persons do not encroach on the area of work.
Consult with the lifting operator to obtain the best and safest method of securing lifting strops or ropes to the equipment and
advise lifting operators of the areas of a system that are susceptible to damage such as antenna fascia’s, swing castings
etc.
Check that the centre of gravity of the equipment cannot cause the lifting strops or ropes to slip or move.
All straps, lifting cables or ropes must be thoroughly checked to ensure that there is no risk of the unit slipping or falling
from the lifting strap or lifting equipment.
WARNING
The transceiver and antenna are heavy items that must be hoisted to the fixing position using suitable lifting equipment, a
secured block and tackle or by rope strops.
During installation, the equipment being lifted must be secured and supported at all times to prevent any risk of falling or
slipping.
Gearboxes must never be lifted by the antenna or swing casting.
The system must NOT be lifted with the antenna assembled onto the unit.
Kelvin Hughes cannot be held responsible for any damage that occurs to supplied or 3rd party equipment as a result of incorrect
lifting procedures or handling or equipment.

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Chapter 3: General Notices
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3 General Notices
3.1 Suggested tools
Item
Description
1
Power drill
2
13 mm socket
3
17mm socket
4
Screwdriver
(“Pozidrive” head)
5
Adhesive tape
6
11 mm drill bit
7
3 mm drill bit
8
17 mm spanner
9
13 mm spanner
10
Torque wrench
3.2 Fitting kit contents
Item
Description
Qty
1
Pedestal
1
2
Mounting template
1
3
Denso paste
1
4
E70352 Voltage
Converter
1
5
E70352 cable clamp
1
6
Lifting eye
3
7
Stud
4
8
Plain Washer
4
9
Spring washer
4
10
Nut
8
11
E70352 mounting
screw
2
12
E70352 cable clamp
mounting screw
3

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Chapter 3: General Notices
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3.3 Disclaimers
WATER INGRESS
Although the waterproof rating capacity of this product exceeds that called for by the IPX6 standard,
water intrusion and subsequent equipment failure may occur if the transceiver enclosure is subjected
to commercial high pressure washing. Kelvin Hughes Ltd will not warrant equipment subjected to high
pressure washing.
EMC INSTALLATION GUIDELINES
The X-band 12kW transceiver system conforms to the appropriate Electromagnetic Compatibility
(EMC) regulations, to minimize electromagnetic interference between equipment and minimize the
effect such interference could have on the performance of your system.
Correct installation is required to ensure that EMC performance is not compromised.
For optimum EMC performance we recommend that wherever possible the equipment and cables
connected to it are:
At least 1m from any equipment transmitting or cables carrying radio signals e.g. VHF radios,
cables and antennas. In the case of SSB radios, the distance should be increased to 2m.
More than 2 m from the path of a radar beam. A radar beam can normally be assumed to spread
20 degrees above and below the radiating element.
The cables supplied and specified for the equipment are correctly fitted and used.
Cables are not cut or extended, unless doing so is detailed in the installation manual.
NOTICE
Where constraints on the installation prevent any of the above recommendations, always ensure
the maximum possible separation between different items of electrical equipment, to provide the
best conditions for EMC performance throughout the installation
SUPPRESSION FERRITES
Cables supplied with the equipment may be fitted with suppression ferrites. These are important for
correct EMC performance. If a ferrite has to be removed for any purpose (e.g. installation or
maintenance), it must be replaced in the original position before the product is used.
Use only ferrites of the correct type as supplied with the cables.
3.4 Declaration of conformity
The X-band 12kW transceiver and open Array radar scanners are in compliance with the essential
requirements of R & TTE directive 1999/5EC.

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4 Typical system

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Chapter 5: Mechanical installation
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5 Mechanical installation
5.1 Location requirements
When selecting a location for the scanner/ transceiver it is important to consider a number of factors.
Additional information on the sighting and position of a radar system is available from Kelvin Hughes
Ltd on request.
HORIZONTAL POSITION
The radar scanner should be positioned as near as possible to your vessels centreline.
HEIGHT
The radar scanner should normally be mounted as high as practical above the waterline.
Mount the scanner above head height out of range of personnel, to avoid mechanical danger and
minimize exposure to electromagnetic radiation.
Radar operates at the line-of-sight, so a high mounting position gives better long range
performance.
Surrounding large objects, in the same horizontal plane, can interfere with the radar signal and
can cause blind areas or shadow sectors and false targets on the radar display (see below).
SHADOW AREAS AND FALSE ECHOES
Mount the radar scanner away from large structures or equipment, such as engine stacks,
searchlights, horns, or masts. These objects may cause shadow areas and false echoes. For
example, if you mount the radar scanner on a mast, echoes from other targets may be reflected from
the mast. It is particularly important to avoid shadow areas near the bow. Raising or even lowering the
radar scanner may help to reduce these effects.
In shadow areas beyond the obstruction there will be a reduction of the beam intensity. There may be
a blind sector if the beam intensity is not sufficient to obtain an echo from an object. This may occur
even at close range. For this reason the angular width and relative bearing of any shadow area must
be determined at installation. You may be able to detect shadow areas or false echoes on your
multifunction display. For example, sea clutter can be used as a good indicator of blind arcs. Dark
sectors on the radar display indicate possible shadowed areas. This information should be posted
near the display unit and operates must be alert for targets in these blind areas.
ACCESS
The radar scanner should be easily accessible to allow maintenance to be carried out safely.
Sufficient clearance must be allowed to fully open the scanner unit for maintenance and service.
MULTIPLE RADAR SCANNERS
If two radar scanners are installed at different locations in a dual radar system, care should be taken
to allow for the difference in position of the radars when switching between the transceivers. This is
especially noticeable at short ranges on larger vessels.
CABLES
All cables should be adequately clamped and protected from physical damage and exposure to heat.
Avoid running cables through bilges or doorways, or close to moving or hot objects. Where a cable
passes through an exposed bulkhead or deck head, use a watertight feed-through.
MOUNTING PLATFORM
The radar scanner must be mounted on a rigid and stable platform. The platform must be capable of
supporting the mass and inertia of the radar scanner under seagoing conditions. The platform should
not twist (causing bearing errors) or be subjected to excessive vibration.

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5.2 Transceiver installation
Before mounting the unit, ensure that you have:
Selected a suitable location.
Identified the cable connections and route that the cables will take.
Prepared suitable lifting equipment for fixing the pedestal to the mounting platform.
The transceiver assembly with the antenna fitted weighs 29 kg
For safety reasons it is recommended that the unit is not fitted by one person. The unit is supplied
with lifting eyes (maximum Safe Working Load (SWL) = 40kg) to facilitate the use of standard lifting
accessories, such as a rope, chain or strop. The SWL of the lifting accessories should be a minimum
of 150kg. Suitable lifting equipment could include a crane, hoist, or an appropriate rigid overhead
structure.
WARNING
DO NOT LIFT THE TRANSCEIVER WITH THE ANTENNA FITTED
NOTICE
DO NOT connect any cables until the following steps have been completed.
1. Check the selected location.
A clear, flat platform is required for mounting
the pedestal unit.
2. Fix the supplied mounting template to the
platform, using masking or self-adhesive tape.
3. Using a 3mm drill bit, drill the 4 holes, as
indicated on the mounting template.
Check that the holes have been drilled in the
correct position.
4. Using an 11 mm drill bit, drill through the 4
holes.
5. Remove the mounting template.
6. Fit the lifting eyes by removing the existing
bolts.
The lifting eyes should be tightened to 7.0Nm
torque.
7. The pedestal unit has a cap fitted over the
open array mounting shaft to protect the
protruding coaxial pin.
This cap must be left in place until the open
array antenna is fitted to the pedestal.
8. Grease the 4 metal studs with the supplied
Denso paste.

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Chapter 5: Mechanical installation
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9. Insert the studs no more than 18 mm into the holes in
the pedestal base, and hand- tighten. 4 spare nuts
are provided which may be used as a temporary
locking nut to aid insertion of the studs into the
pedestal.
If the supplied studs are not long enough for the
mounting surface thickness, use M10 stainless steel,
grade A4-70 studding of a suitable length.
10. Using suitable lifting equipment (such as a rope or
chain) attached to the lifting eyes; raise the pedestal
over the mounting surface. Carefully lower into
position, taking care that the studs pass through the
holes without damaging the threads. Ensure that the
front of the pedestal is pointing towards the bow of
the vessel.
11. Grease the studs with the supplied Denso paste.
12. Use the 4 nuts and associated washers to secure the
pedestal to the platform. Ensure all 4 sets of nuts and
washers are used to secure the pedestal to the
mounting platform.
Tighten each nut to 30Nm torque.
13. There should be no more than 6 mm of excess stud
below the nut. Cut-off any excess stud.
REMOVING THE RADAR PEDESTAL LIFTING EYES
1. Loosen the first lifting eye securing bolt, enough to remove the lifting eye.
2. Once the lifting eye is removed, re-tighten the bolt to 7Nm torque.
3. Repeat Steps 1 to 2 to remove all lifting eyes.

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5.3 Antenna installation
CAUTION
Ensure that the antenna does not come into contact with the delicate protruding coaxial pin, this is a
critical component and should be treated with caution.
Follow all the instructions provided on the following page and ensure that the alignment guides are
used.
Before attaching the antenna to the pedestal unit, ensure that:
The pedestal base is securely fixed to the platform.
The power/ data cable is NOT attached.
The pedestal unit has a cap fitted over the open array mounting shaft to protect the
protruding co-axial pin. This cap must remain in place until you are ready to fit antenna to
the pedestal unit.
The pedestal power switch is in the OFF position.
1. Fit the 4 threaded alignment
guides to the studs on the
underside of the antenna.
2. Ensure a close fit. The
alignment guides are essential
to help prevent damage to the
coaxial pin.
3. Remove the protective cap from
the antenna shaft. Retain the
cap for future use.
4. Position the antenna mounting
bracket on the Port to Starboard
axis of the pedestal.
5. Lift the antenna into position,
ensuring it is in the correct
orientation and that the threaded
alignment guides are fitted.
Carefully align and slowly lower
the antenna.
6. Once the antenna is in position, remove the alignment guides.
7. Grease the 4 securing studs with the supplied Denso paste.
8. Use the 4 nuts and associated washers to secure the antenna to the pedestal, as shown in the
following diagram.
9. Tighten each nut to 10 Nm torque.

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5.4 E70352 Power supply
CAUTION
This product is NOT approved for use in hazardous/ flammable atmospheres such as in an engine
room or near fuel tanks.
POWER SUPPLY LOCATION REQUIREMENTS
The E70352 is designed to be internally bulkhead mounted on a flat vertical surface.
VENTILATION
Ensure that equipment is mounted in a compartment of suitable size.
Ensure that ventilation holes are not obstructed.
Allow adequate separation between equipment.
CABLES
Ensure the unit is mounted in a location which allows proper routing and connection of cables:
Minimum bend radius of 100 mm (3.94 in) unless otherwise stated.
Use cable supports to prevent stress on connectors.
The maximum length of cable between the DC power source and the E70352 should not
normally exceed 6m.
All power cable lengths should be kept as short as possible.
See section 7.3 for additional details.
WATER INGRESS
The E70352 is splash proof and suitable for internal mounting below decks only.
ELECTRICAL INTERFACE
Select a location that is far enough away from devices that may cause interference, such as motors,
generators and radio transmitters/ receivers.
POWER SUPPLY
Select a location that is as close as possible to the vessels DC power source. This will help to keep
cable runs to a minimum.

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POWER SUPPLY INSTALLATION
Before mounting the unit, ensure that you have:
Selected a suitable location. The unit is designed to be internally mounted in a vertical position.
Identified the cable connections and route that the cables will take.
NOTICE
Do NOT connect any cables to the power supply until the following steps have been completed.
1. Check the selected location for the unit. The
E70352 requires a clear, flat area with suitable
space for routing the cables below the unit.
2. Hold the E70352 in place in the required
mounting location.
3. Using a pencil, mark the drilling area inside the
mounting lug on each side of the E70352 unit.
4. Using a 3 mm drill bit, drill a hole through the
pencil marks.
5. Align the E70352 mounting lugs with the drill
holes.
6. Hold the E70352 in place.
7. Using a suitable screwdriver, screw the self-
tapping mounting screws through the mounting
lug holes, into the drilled holes.
8. Connect the cables, according to the instructions
provided in this handbook.
9. Hold the cable clamp in place over the cables,
approximately 50 mm below the mounted
E70352 unit.
10. Using a pencil, mark the drilling area inside each mounting bracket hole.
ENSURE THE CABLES DO NOT COVER THE HOLES.
11. Using a 3mm drill bit, drill a hole through the pencil marks.
12. Hold the cable clamp in place, each hole aligned with the drill holes.
13. Using a suitable screwdriver, screw the self-tapping mounting screws through the bracket holes,
into the drilled holes.

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Chapter 5: Mechanical installation
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5.5 DIMENSIONS
5.5.1 Transceiver
V.M. 1 16/05/2016
A1
1
KELVIN HUGHES X-BAND
12kW UPMAST
TRANSCEIVER
RYM-E70351 / RYM-E70350
V.M.
REL'SD

X-band 12kW Upmast Magnetron Transceiver
Chapter 5: Mechanical installation
HBK-2300-3 Issue 2
Page 20 of 40
5.5.2 Mounting hole dimensions
Note: A drilling template is provided as part of the fitting kit.