RAD4K, 6K, 12K AND 25K RADARS INSTALLATION MANUAL Part No. GMRadIM Rev. E1 Northstar 30 Sudbury Road Acton, Massachusetts 01720 a unit of Brunswick New Technologies Marine Electronics www.NorthstarNav.com Service: 978/897-6600 Sales: 800/628-4487 Contents SECTION ONE: Introducing the Northstar radar SECTION TWO: Installing and wiring the radar ------------------- 1 -------------------- 3 Installing the antenna - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 Installing the control box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8 Wiring the radar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 SECTION THREE: Setting up the radar (new navigator software) - - - 17 17 19 22 24 Configuring the navigator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Calibrating the radar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting the appearance settings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Finishing up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION FOUR: Setting up the radar (older navigator software) - - - 25 Configuring the navigator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Calibrating the radar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Gain adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31 SECTION FIVE: Using manual control functions - - - - - - - - - - - - - - - - - - - 33 Gain and clutter adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Other functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35 SECTION SIX: Servicing the radar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37 37 38 38 38 Contacting Northstar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hearing from you - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Using the Dealer Express web pages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Returning a radar for service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - APPENDIX A: Specifications and Drawings - - - - - - - - - - - - - - - - - - - - - - - 39 APPENDIX B: Manual Tuning Procedure - - - - - - - - - - - - - - - - - - - - - - - - - 43 APPENDIX C: Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 SECTION ONE: Introducing the Northstar radar 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. The Northstar radar is designed as an option available for the Northstar 958 and 6000i navigators. 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. 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 interface connector, pins 1 and 3). Without the heading sensor, the radar image will not line up properly with the chart. The Northstar 958 and 6000i accept the following standard NMEA 0183 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 Components supplied with each of the four radar models are listed on the next page. Radar Installation Manual, Rev. E1 Page 1 SECTION ONE: Introducing the Northstar radar TABLE 1: Radar parts list Radar: Description (Qty.) Scanner (1 ea.) Control box (1 ea.) 10-meter cable (1 ea.) Parts kit (1 ea.) Power Switch (1 ea.) Terminal strip (2 ea.). RAD4KD-A 4kW with dome antenna RSC715 MDS2 WC10D RAD4K35-A 4kW with 3.5' open array antenna RSC716 MDS2 WC10OA RAD6K45-A 6kW with 4.5' open array antenna RSC717 MDS3 WC10OA RAD12K65-A 12kW with 6.5' open array antenna RSC718 MDS3 WC10OA RAD25K65-A 25kW with 6.5' open array antenna RSC719 MDS4 WC10OA MDS2-PK ST165 MDS2-PK ST165 MDS3/4-PK ST165 MDS3/4-PK ST165 MDS3/4-PK ST165 TS101 TS101 TS101 TS101 TS101 Optional cables are available in 15-, 20- and 30-meter lengths. TABLE 2: Parts kit contents Radar: Parts kit: Mounting bolts (4 ea.) Power cable (1 ea.) Screws (4 ea.) Spare fuses RAD4KD-A MDS2-PK M10x25 hex bolts WA585 RAD4K35-A MDS2-PK M10x25 hex bolts WA585 RAD6K45-A MDS3-PK M12x55 hex bolts WA585 RAD12K65-A MDS3-PK M12x55 hex bolts WA585 RAD25K65-A MDS4-PK M12x55 hex bolts WA585 TPT5x20U self-tapping screws MF61NN10 10A fuse (2 ea.) MF61NN8 8A fuse (1 ea.) MF51NN250V5A 5A fuse (2 ea.) ES3-3150 3.15A fuse (1 ea.) TPT5x20U self-tapping screws MF61NN10 10A fuse (2 ea.) MF61NN8 8A fuse (1 ea.) MF51NN250V5A 5A fuse (2 ea.) ES3-3150 3.15A fuse (1 ea.) TPT5x20U self-tapping screws MF61NN10 10A fuse (2 ea.) MF61NN8 8A fuse (1 ea.) MF51NN250V5A 5A fuse (2 ea.) ES3-3150 3.15A fuse (1 ea.) TPT5x20U self-tapping screws MF61NN10 10A fuse (2 ea.) MF61NN8 8A fuse (1 ea.) MF51NN250V5A 5A fuse (2 ea.) ES3-3150 3.15A fuse (1 ea.) TPT5x20U self-tapping screws MF61NN10 10A fuse (2 ea.) MF61NN8 8A fuse (1 ea.) MF51NN250V5A 5A fuse (2 ea.) ES3-3150 3.15A fuse (1 ea.) Page 2 Radar Installation Manual, Rev. E1 SECTION TWO: Installing and wiring the radar System diagram A configuration diagram for a fully-optioned Northstar system with radar, heading sensor and echosounder is shown in Figure 1. This diagram provides an overview of the interconnection between components. 2301, AN150 or AN156 GPS/WASS Antenna Prefabricated Antenna Cable Aux Port VGA out NTSC in Northstar Navigator WA215 I/O cable Scanner Array (4, 6, 12 or 25kW) Northstar 4kW Dome Radar NMEA device (Autopilot repeater, etc.) NMEA Port 1 out NMEA Port 1 in NMEA Port 2 In and Out Ship's power Ship's power I/O & Power Interface (Terminal Strips) 10, 15, 20 or 30m prefabricated cable Heading sensor Northstar Echo Sounder Ship's power Northstar Radar Interface Box MDS 2/3/4 Ship's power Transducer Figure 1: System diagram Radar Installation Manual, Rev. E1 Page 3 SECTION TWO: Installing and wiring the radar Installing the antenna CAUTION! To eliminate interference, install the antenna away from GPS and radio receiver antennas, including SatNav and satellite TV antennas. 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) Page 4 Radar Installation Manual, Rev. E1 SECTION TWO: Installing and wiring the radar Figure 2: Shifting from the keel 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. Figure 3: Sufficient dip angle Mounting the 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 4: Using a mounting base Radar Installation Manual, Rev. E1 Page 5 SECTION TWO: Installing and wiring the radar NOTE: When the radar platform or mounting bracket has a curvature of more than 2mm, repair it or use spacers. 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 thinner than that, use bolts specified in Table 3 or Table 4 on page 8. See Figure 6 or Figure 7 below for details on bolting the antenna to the mounting base. Figure 5: Hole positions for mounting antennas (radome or open array) Figure 6: Mounting the radome antenna Page 6 Radar Installation Manual, Rev. E1 SECTION TWO: Installing and wiring the radar Figure 7: Mounting the open array antenna Attaching the 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. Antenna radiation surface Arrows Figure 8: Attaching the array Radar Installation Manual, Rev. E1 Page 7 SECTION TWO: Installing and wiring the radar TABLE 3: Bolts for mounting radome antenna Thickness of mounting base 0.04-0.16 in. (1 - 4mm) 0.16-0.35 in. (4 - 9mm) 0.35-0.55 in. (9 -14mm) 0.55-0.75 in. (14 -19mm) Radome mounting bolts M10 × 15 (1.5mm pitch) M10 × 20 (1.5mm pitch) M10 × 25 (1.5mm pitch) M10 × 30 (1.5mm pitch) Material Stainless Stainless Stainless Stainless Comments Included TABLE 4: Bolts for mounting open array antenna Thickness of mounting base 0.04-0.16 in. (1 - 4mm) 0.16-0.35 in. (4 - 9mm) 0.35-0.55 in. (9 -14mm) 0.55-0.75 in. (14 -19mm) Open array mounting bolts M12 × 45 (1.5mm pitch) M12 × 50 (1.5mm pitch) M12 × 55 (1.5mm pitch) M12 × 60 (1.5mm pitch) Material Stainless Stainless Stainless Stainless Comments Included Installing the control box For the control-box dimensional drawing, see Figure 18 on page 41. Do not install the control box in the bilge. Replacing the fuse You must use proper rating ...