NorthStar Ethernet Radar User manual

N
ORTHSTAR
E
THERNET RADAR
I
NSTALLATION
M
ANUAL
Part No. GMEKRadIM
Rev. A
Northstar
a unit of Brunswick New Technologies Marine Electronics
30 Sudbury Road
Acton, Massachusetts 01720
www.NorthstarNav.com
Service: 978/897-6600
Sales: 800/628-4487

Contents
SECTION ONE: Introducing the Northstar radar - - - - - - - - - - - - - - - - - - - 1
SECTION TWO: Installing and wiring the radar - - - - - - - - - - - - - - - - - - - - 3
System diagram
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Installing the radar antenna
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Installing the control box
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Wiring the radar
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
SECTION THREE: Setting up the radar - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Calibrating the radar
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
SECTION FIVE: Using manual control functions - - - - - - - - - - - - - - - - - - - 23
Gain and clutter adjustments
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
Other functions
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
SECTION SIX: Servicing the radar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Contacting Northstar
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
Hearing from you
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
Returning a radar for service
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
APPENDIX A: Specifications and Drawings - - - - - - - - - - - - - - - - - - - - - - - 27
APPENDIX B: Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31

Ethernet Radar Installation Manual, Rev. A Page 1
SECTION ONE: Introducing the
Northstar radar
The Northstar Ethernet Radar is designed as an option available for the Northstar 972 navigator.
A radar unit should only be installed by a qualified marine technician, as potentially lethal high
voltage is present, along with heavy rotating parts. There is a transmit interlock that prevents radar
transmissions if the array is not rotating. However, high voltage remains for a period of time after the
system is turned off. If you are not familiar with this type of electronics, consult with a trained
service or installation technician before attempting to service any part of the equipment.
Installation includes mechanical mounting and electrical wiring, followed by properly configuring
the navigator to work with the radar, and finally adjusting the radar for proper performance.
Don’t take any shortcuts, and follow these instructions carefully.
Components supplied with each of the five radar models are listed on the next page.
WARNING!
Always stay away from any type of radar antenna to
avoid exposure to radiation!
An open array antenna may start rotating at any time.
Before starting antenna operation, always move all
personnel away from the antenna to prevent accidents.
It is highly recommended that an open array antenna be
installed as high as possible (such as on the fly bridge,
radar mast, etc.) so that no person can ever be near
enough to sustain injury.
NOTE:
For the radar overlay to function properly on the chart screen, you must
correctly
install and calibrate a separate heading sensor (using the
navigator’s NMEA Input Port 1 interface connector, pins 1 and 3). Without
the heading sensor, the radar image will not line up properly with the chart.
The Northstar 972 accepts the following standard NMEA0183 sentences to
obtain heading information from a sensor: HDG, HDT, OSD, HCC, HCD,
and HDM.
For sensor installation and calibration instructions, see the sensor
manufacturer’s installation manual. In addition, the navigator must be
calibrated to the heading sensor as described on page 21.

SECTION ONE: Introducing the Northstar radar
Page 2 Ethernet Radar Installation Manual, Rev. A
∗
Optional cables are available in 15-, 20- and 30-meter lengths.
TABLE 1: Radar parts list
Radar: R4KDE-A R4KE35-A R6KE45-A R12KE65-A R25KE65-A
Description
(Qty.) 4kW with dome antenna 4kW with 3.5’ open array
antenna
6kW with 4.5’
open array
antenna
12kW with 6.5’
open array
antenna
25kW with 6.5’
open array
antenna
Scanner
(1 ea.) RSC715 RSC716 RSC717 RSC718 RSC719
Controlbox
(1 ea.) MDS5 MDS5 MDS6 MDS6 MDS6
10-meter
cable
∗
(1 ea.)
WC10D WC10OA WC10OA WC10OA WC10OA
Parts kit
(1 ea.) MDS2-PK MDS2-PK MDS3/4-PK MDS3/4-PK MDS3/4-PK
Power
Switch
(1 ea.)
ST165 ST165 ST165 ST165 ST165
TABLE 2: Parts kit contents
Radar: 4KDE-A R4KE35-A R6KE45-A R12KE65-A R25KE65-A
Parts kit: MDS2-PK MDS2-PK MDS3-PK MDS3-PK MDS4-PK
Mounting
bolts (4 ea.)
M10x25 hex bolts M10x25 hex bolts M12x55 hex bolts M12x55 hex bolts M12x55 hex bolts
Power
cable (1
ea.)
WA585 WA585 WA585 WA585 WA585
Screws
(4 ea.)
TPT5x20U
self-tapping
screws
TPT5x20U
self-tapping
screws
TPT5x20U
self-tapping
screws
TPT5x20U
self-tapping
screws
TPT5x20U
self-tapping
screws
Spare
fuses
MF61NN10
10A fuse (2 ea.)
MF61NN8
8A fuse (1 ea.)
MF51NN250V5A
5A fuse (2 ea.)
ES3-3150
3.15A fuse (1 ea.)
MF61NN10
10A fuse (2 ea.)
MF61NN8
8A fuse (1 ea.)
MF51NN250V5A
5A fuse (2 ea.)
ES3-3150
3.15A fuse (1 ea.)
MF61NN10
10A fuse (2 ea.)
MF61NN8
8A fuse (1 ea.)
MF51NN250V5A
5A fuse (2 ea.)
ES3-3150
3.15A fuse (1 ea.)
MF61NN10
10A fuse (2 ea.)
MF61NN8
8A fuse (1 ea.)
MF51NN250V5A
5A fuse (2 ea.)
ES3-3150
3.15A fuse (1 ea.)
MF61NN10
10A fuse (2 ea.)
MF61NN8
8A fuse (1 ea.)
MF51NN250V5A
5A fuse (2 ea.)
ES3-3150
3.15A fuse (1 ea.)

Ethernet Radar Installation Manual, Rev. A Page 3
SECTION TWO: Installing and
wiring the radar
System diagram
A configuration diagram for a fully-optioned Northstar 972 system with radar, heading sensor and
echosounder is shown in Figure 1. This diagram provides an overview of the interconnection
between components.
2301
GPS/WASS
Antenna
GPS
Port
Northstar
Echo
Sounder
Transducer
Northstar
Radar
Interface
Box
MDS 5/6
Heading
sensor
NMEA device
(Autopilot
repeater, etc.)
Dome Radar
(4kW)
Scanner Array
(4, 6, 12 or 25kW)
10, 15, 20 or 30m
prefabricated
cable
WA215
I/O cable
Aux Port
VGA out
NTSC in
NMEA Port 1 in
NMEA Port 1 out
Ship's
power
Ship's
power
Ship's
power
Northstar
972
Processor
Ship's
power
972
Display
Ship's
power
NMEA Port
Ethernet
Control
Data
Figure 1: System diagram

SECTION TWO: Installing and wiring the radar
Page 4 Ethernet Radar Installation Manual, Rev. A
Installing the radar antenna
Choosing the antenna location
The radar’s ability to detect targets depends greatly on the position of its antenna. The ideal antenna
location is high above the ship's keel line where there aren’t any obstacles. This ideal location is
limited by various factors; therefore, consider the following when choosing the antenna location:
• Do install the antenna as high as possible (after considering the structure of the vessel’s
hull, the weight of the antenna, and how easy it will be to maintain the antenna). The
higher the installation position, the longer the radar ranging distance.
• Do install the antenna away from masts or other obstructions. If the antenna isn’t higher
than obstructions, radar waves may be blocked, creating shadow zones or generating false
echoes.
• Do install the antenna closer to the vessel’s bow, for a clear view to the front. When
installing the antenna on a mast, place it in front of the mast. If obstacles can’t be avoided
for vessel structural reasons, see “Shifting the antenna away from the keel line,” described
below.
• Do install the antenna as far away as possible from the antennas of other equipment, such
as direction finders, GPS equipment, radio receivers, etc. Radar scanners may cause
interference with radio receivers.
• Do keep the connecting cable as short as possible. Whenever possible, keep the distance
from the antenna to the control box within the standard cable length of 10 meters. If you
must use longer cable, do not exceed 30 meters.
• Don’t install the antenna where it may be subjected to smoke or hot air from smokestacks
or heat from lamps.
Shifting the antenna away from the keel line
By shifting the antenna position from the keel line to starboard, it’s possible to move shadow zones
to the port side. This makes it possible to keep a clear view to the bow. You can calculate the distance
to be shifted, depending on the distance from the antenna to any obstacles, by using the following
equation (Ls = distance to be shifted from keel line; D = diameter of obstacle on keel line; and R =
distance from antenna to obstacle):
Ls=0.4R+D/2 (when R<15m)
Ls=0.025R+D/2 (when R>=15m)
CAUTION!
To eliminate interference, install the antenna away from GPS and radio
receiver antennas, including SatNav and satellite TV antennas.

SECTION TWO: Installing and wiring the radar
Ethernet Radar Installation Manual, Rev. A Page 5
Obtaining sufficient dip angle
Raise the antenna position above on-board obstacles to avoid shadow zones. Dip angle is the angle
between a horizontal line and the line of sight from the antenna to the obstacle. By maintaining a dip
angle greater than 5 degrees, you may be able to prevent mid- and long-distance shadow zones. The
radar can’t detect objects below its line of sight.
Mounting the radar antenna
It may be easier to install the antenna by fabricating a mounting base, as shown below, but you can
also install the antenna directly to a rigid, flat surface, such as the roof. Pay attention to the water
drain tube at the bottom of the antenna.
Figure 2: Shifting from the keel
Figure 3: Sufficient dip angle
Figure 4: Using a mounting base

SECTION TWO: Installing and wiring the radar
Page 6 Ethernet Radar Installation Manual, Rev. A
Referring to Figure 5 below and the supplied full-size antenna mounting templates, drill holes at the
specified locations in the mounting base. Using these holes and hexagonal bolts, install the antenna
to the mounting base. Use silicone to stop the bolts from loosening. The bolts supplied will suffice for
mounting base thicknesses of 0.35 to 0.55 inch (9 to 14 mm). If the mounting base is thicker or thin-
ner than that, use bolts specified in Table 3 or Table 4 on page 7. See Figure 6 or Figure 7 below for
details on bolting the antenna to the mounting base.
NOTE:
When the radar platform or mounting bracket has a curvature of more than
2mm, repair it or use spacers.
Figure 5: Hole positions for mounting antennas (radome or open array)

SECTION TWO: Installing and wiring the radar
Ethernet Radar Installation Manual, Rev. A Page 7
Mounting a radome
TABLE 3: Bolts for mounting radome antenna
Mounting an open array
Remove the protective cap covering the rotary coupler on the top of the antenna. Match the antenna
radiation direction to the direction of the arrows on the rotation base as shown in Figure 8, and
secure the antenna into place using four M8 bolts.
Thickness of
mounting base Radome mounting bolts Material Comments
0.04-0.16 in. (1 - 4mm) M10 × 15 (1.5mm pitch) Stainless
0.16-0.35 in. (4 - 9mm) M10 × 20 (1.5mm pitch) Stainless
0.35-0.55 in. (9 -14mm) M10 × 25 (1.5mm pitch) Stainless Included
0.55-0.75 in. (14 -19mm) M10 × 30 (1.5mm pitch) Stainless
Figure 6: Mounting the radome antenna
Figure 7: Mounting the open array antenna

SECTION TWO: Installing and wiring the radar
Page 8 Ethernet Radar Installation Manual, Rev. A
Installing the control box
For the control-box dimensional drawing, see Figure 17 on page 29.
Do not install the control box in the bilge or areas with high level of humidity. The control box is not
waterproof.
Replacing the fuse
You must use proper rating fuses to safely operate the radar control box. Fuses marked with an
asterisk ( ∗ ) in the following tables are installed in the set when shipped.
TABLE 5: Fuse requirements for MDS-5 (with 4 kW radome)
TABLE 4: Bolts for mounting open array antenna
Thickness of
mounting base Open array mounting bolts Material Comments
0.04-0.16 in. (1 - 4mm) M12 × 45 (1.5mm pitch) Stainless
0.16-0.35 in. (4 - 9mm) M12 × 50 (1.5mm pitch) Stainless
0.35-0.55 in. (9 -14mm) M12 × 55 (1.5mm pitch) Stainless Included
0.55-0.75 in. (14 -19mm) M12 × 60 (1.5mm pitch) Stainless
Supply voltage Main fuse Motor fuse
12 VDC 8A/250V or 125V
∗
(6.3Ø x 32mm) T3.15A/250V or 125V
∗
(5Ø x 20mm)
24 VDC 8A/250V or 125V (6.3Ø x 32mm) T3.15A/250V or 125V (5Ø x 20mm)
Arrows
Antenna
radiation
surface
Figure 8: Attaching the array

SECTION TWO: Installing and wiring the radar
Ethernet Radar Installation Manual, Rev. A Page 9
TABLE 6: Fuse requirements for MDS-5 (with 4 kW open array)
TABLE 7: Fuse requirements for MDS-6 (with 6 kW open array)
TABLE 8: Fuse requirements for MDS-6 (12 kW or 25 kW open array)
Wiring the radar
Regardless of the type of antenna, when connecting the cables, keep in mind the following:
•Do not tie the radar cables, especially the power supply cable, together with the cables of
other equipment
•Do leave service and drip loops so you can easily remove the control box
•Do mount the control box in a dry area protected from moisture and humidity
•Do lay the cable along the vessel’s hull or wall surface, and secure it at intervals of about
16” (40 centimeters)
•The 25 kW unit operates on a 24- or 32-volt system only
Figure 9 shows the connections to the radar control box.
Supply voltage Main fuse Motor fuse
12 VDC 10A/250V or 125V (6.3Ø x 32mm) 5A/250V or 125V (5Ø x 20mm)
24 VDC 8A/250V or 125V∗(6.3Ø x 32mm) T3.15A/250V or 125V∗(5Ø x 20mm)
Supply voltage Main fuse Motor fuse
12 VDC 8A/250V or 125V (6.3Ø x 32mm) 5A/250V or 125V (5Ø x 20mm)
24 VDC 8A/250V or 125V∗(6.3Ø x 32mm) T3.15A/250V or 125V∗(5Ø x 20mm)
Supply voltage Main fuse Motor fuse
12 VDC (MDS-3 only) 10A/250V or 125V (6.3Ø x 32mm) 5A/250V or 125V (5Ø x 20mm)
24 VDC 8A/250V or 125V∗(6.3Ø x 32mm) T3.15A/250V or 125V∗(5Ø x 20mm)

SECTION TWO: Installing and wiring the radar
Page 10 Ethernet Radar Installation Manual, Rev. A
Install the radar antenna cable as described below, under either Radome cable connection or Open
array antenna connection. Important: If connectors are removed for cable routing, refer to Table 9
below when reconnecting to the radar scanner.
Radome cable connection
Use the following instructions for connecting to cable to an enclosed radome.
1. Turn the power off.
2. Remove the upper part of the radome from the scanner, lifting it vertically to avoid bumping
it against the antenna (four screws hold it in place).
3. Remove the tape securing the antenna.
4. Remove the shield cover located on the backside (there are four screws).
TABLE 9: Antenna cable wire functions
X11 Connector X12 Connector
Pin Color Function Pin Color Function
1 Violet +250V 1 Blue +24V
2 N/C 2 N/C
3 Yellow GND 3 Orange +12V
4 Red Ships + 4 Braid of Red DAT-R
5 Yellow Ships + 5 Red DAT
6 Green Ships – 6 Braid of Brown BP/SHF-R
7 Blue Ships – 7 Brown BP/SHF
8 Braid of Gray V/TRG-R
9 Gray V/TRG
Figure 9: Control box connectors

SECTION TWO: Installing and wiring the radar
Ethernet Radar Installation Manual, Rev. A Page 11
5. See Figure 10 on next page: Remove the cable compression plate and rubber ring and pass
the cable up through the opening. Replace the rubber ring and secure the cable with the
compression plate. Attach the 7-pin connector to X11 and the 9-pin connector to X12 of the
printed circuit board (PCB).
6. Replace the aluminum shield cover. Lay the cable shield into the channel machined into the
aluminum housing. Be careful that the cable won’t get caught between the main unit and
the cover. Make sure the antenna rotates freely and that the scanner cable does not obstruct
the rotation of the antenna.
7. Replace the upper part of the radome, making sure you don’t bump it against the antenna.
Make sure the radome cover is positioned in the correct direction, as shown in Figure 11. The
upper and lower parts of the radome each have four alignment markings indicating screw
positions.
8. Connect the antenna cable to the plug labeled SCANNER on the rear panel of the control
box. Be sure to secure the rubber boot around the cable connector rim.
Open array cable connection
1. Turn the power off.
2. Use a socket wrench to remove the four bolts securing the back cover of the scanner.
Remove the two bolts securing the transceiver (see Figure 12).
3. Remove the connectors to the motor (labeled X1 or J5) and to the heading switch (X2 or J3).
Pull out the transceiver.
Figure 10: Connecting the radome cabl
e
Figure 11: Attaching the radome cover

SECTION TWO: Installing and wiring the radar
Page 12 Ethernet Radar Installation Manual, Rev. A
“X” numbers are found on the 4kW unit, and “J” numbers on the larger units.
4. Remove the two mounting bolts securing the clamp plate at the cable entrance.
5. Remove the metal clamp plate and rubber seal that secure the cable. Pass the cable through
as shown in the diagram; replace the above items and tighten the bolts.
6. Return the transceiver to its original position and secure it with the bolts you removed.
7. Connect the 7-pin connector to the point labeled either X11 or J2 and the 9-pin connector to
either X12 or J1 on the printed circuit board. Reconnect the two connectors that you
removed in Step 4.
8. Re-attach the scanner cover (be careful not to pinch any internal cables when reattaching it).
9. Connect the antenna cable to the SCANNER connector on the control box. Be sure to secure
the rubber boot around the cable connector rim.
Connecting a ground wire
Connect a grounding wire from one of the bolts on the scanner base, as shown in Figure 13 below
(the crimp terminal and grounding wire are installer-supplied).
Cable shield
terminal
Mounting bolts (2)
Scanner
housing
Connecting
cable Cable inlet
Rubber ring
Keep the cable shield braid
as short as possible
Cable jacket
must not exceed
1/4 inch
Transceiver unit
mounting bolts (2)
Remove connectors
Cable clamp
ring
Figure 12: Connecting the open array antenna cable

SECTION TWO: Installing and wiring the radar
Ethernet Radar Installation Manual, Rev. A Page 13
Connecting the power cable
The MDS-5 and MDS-6 units are designed for 12/24/32-volt installations when used at 4, 6 or
12kW. The MDS-6, when used at 25kW operates on 24 or 32 VDC only.
Power should be fed through a switch and protective fuses (or circuit breakers).
To connect the power cable:
1. Plug the power cable into the POWER on the control box, and connect to power supply as
shown below.
2. Locate the fuse and connector part in a dry area with no water splash.
Figure 14 shows the power connector wiring, to be used if the installer chooses to remove and
reinstall the connector to run the cable through small openings.
CAUTION! Do not apply over 41.6V to the radar or it may be damaged.
Figure 13: Grounding the antenna to earth
1
2
3
4
5DC –
DC +
NC
NC
Gnd
Radar Power Cable
Connector End View
Pin Function Color (new style) Color (old style)
1 DC Power – Gnd Black Black
2 DC Power – A+ Red White
3 Not Connected
4 Not Connected
5 Equipment Ground Green Gray
Figure 14: Power cable pin connections

SECTION TWO: Installing and wiring the radar
Page 14 Ethernet Radar Installation Manual, Rev. A
Radar power control
Important: Blue and Green wires from the radar control box are for power control and
must be wired according to one of the options shown below.
Electrical power for the radar is controlled by the blue and green wires in the power control cable.
When these wires are connected to each other, the radar powers up and enters standby mode. When
they are not connected, the radar is turned off (although it still draws a tiny amount of power).
Connect the blue and green wires in any one of the following ways:
•Option 1: Connect the blue and green wires to an S.P.S.T switch as shown in Figure 15 to
control the radar’s power An appropriate switch is included with the radar.
•Option 2: Permanently connect the blue and green wires to each other, and control the
radar’s power from a switched circuit breaker at the mains circuit panel.
Note: The option of controlling the radar power using the “honk” output of the 972 processor is
not available at present.
Connecting the radar control box to the navigator
The radar control box is connected to the 972 Processor by means of a standard Ethernet cable.
If no other devices are connected to this network, use a “crossover cable.”
If other devices are connected, such as additional control heads, use an Ethernet switch and “straight
cables.”
Wiring the heading sensor
See Table 10 for general heading sensor wiring.
Figure 15: Using a switch to control radar power

SECTION TWO: Installing and wiring the radar
Ethernet Radar Installation Manual, Rev. A Page 15
Wiring for Robertson RFC35N and KVH AutoComp 1000 Heading Sensors is shown below.
TABLE 10: Wiring the heading sensor
HEADING SENSOR NAVIGATOR I/O CABLE (P/N WA215)
NMEA Data Out – Blue NMEA Port 1 In B 1
NMEA Data Out + Brown NMEA Port 1 In A 3
ROBERTSON RFC35N HEADING
SENSOR NORTHSTAR NMEA 18-PIN CONNECTOR
Wire Color Description Pin No. Wire Color Description
Brown Tx– Data Ground 1 Blue NMEA Port 1 in B
White Tx + Data Transmit 3 Brown NMEA Port 1 In A
Green Rx– Data Ground Not Connected
Yellow Rx+ Data Receive Not Connected
Pink Vin+ Power A+ Ship’s Power Supply, Fused, 12 VDC
Gray Vin– Power Ground Ship’s Power Ground

SECTION TWO: Installing and wiring the radar
Page 16 Ethernet Radar Installation Manual, Rev. A
KVH AUTOCOMP 1000 HEADING
SENSOR (P/N 01-0118-0001) NORTHSTAR NMEA 18-PIN CONNECTOR
Wire Color Description Pin No. Wire Color Description
Orange NMEA 0183 Out – 1 Blue NMEA Port 1 in B
Green NMEA 0183 Out + 3 Brown NMEA Port 1 In A
White Damping 0 Connect to Power Ground
Brown Damping 1 Connect to Power Ground
Blue AutoComp Disable Do not connect. Cap and Insulate
Red 12 VDC Power Ship’s Power Supply, Fused, 12 VDC
Black Power Ground Ship’s Power Ground
Drain, Foil,
Shield
not used Not Connected