Navtech Radar TS350X-001 User Guide

Document No: MAINT0111

Date: September 2012

Installation Guide

for

Navtech Radar

I Series Radar Sensors

Navtech Radar Ltd.
Tel: [phone]
email: [e-mail]

Document History

Issue

Date

Description

1.0

19/09/2012

First Draft

1.1

14/03/2013

Update for FCC statement

1.2

20/03/2013

Updated the FCC statement

Document History

Installation Guide –I Series i
Doc ref: MAINT- 0111 Issue 1.2

Contents

1. Introduction 1-1

1.1 Scope 1-1

1.2 Essential Items 1-1

1.3 Pre requisites to working on a Container Crane & Bulk Loaders 1-2

1.4 Radar sensor 1-1

2. Installing the Radar hardware 2-3

2.1 Overview 2-3

2.2 Radar sensor locations 2-4

2.2.1 Location 2-4

2.2.2 Orientation 2-9

2.3 Mounting radar sensor 2-10

2.4 Connecting radar sensor 2-11

2.5 Preparing the laptop 2-13

2.5.1 Factory settings 2-13

2.5.2 Changing factory settings 2-13

2.6 Connecting your laptop 2-13

2.7 Levelling radar sensor 2-13

2.7.1 Adjusting radar 2-15

2.8 Securing the radar 2-16

2.9 Confirming sensor coverage 2-16

3. Health & Safety 3-17

3.1.1 General 3-17

3.1.2 Design 3-17

3.1.3 Maintenance 3-17

Annex A Using SPx RadarView 1
Annex B Sample Brackets 1
Annex C Specifications 1

C.1 Radar power cable 1
C.2 Radar Cat 5E cable 1
C.3 Radar power cable connector (radar end) 1
C.4 Radar Cat 5E cable connector (radar end) 3

Annex D Construction of test target 1
Annex E Radar sensor configurations 2

Installation Guide –I Series ii
Doc ref: MAINT- 0111 Issue 1.2

Contents

List of figures

Figure 1 Radar sensor - isometric views ....................................................................................... 1-1

Figure 2 Radar sensor - dimensions .............................................................................................. 1-2

Figure 3 Single radar mounted on the underside of a bulk loader ................................................. 2-4

Figure 4 A single radar detects objects as the boom luffs ............................................................. 2-5

Figure 5 Detection on either side of a boom with a moveable loading chute, with 2 radar ........... 2-6

Figure 6 This loader is shown with combined horizontal and vertical scanning radar ................... 2-7

Figure 7 The scan plane of vertically scanning radar sensors ....................................................... 2-8

Figure 8 Single Radar on an STS, container handling crane......................................................... 2-9

Figure 9 Plan view of a radar, showing the encoder zero angle .................................................. 2-10

Figure 10 Mounting radar on posts/brackets, for both vertical and horizontally scanning radar ... 2-10

Figure 11 Levelling adjustment ...................................................................................................... 2-11

Figure 12 Connections to radar sensor .......................................................................................... 2-11

Figure 13 Connecting radar sensor ................................................................................................ 2-12

Figure 14 Horizontal radar sensor misses target B ........................................................................ 2-14

Figure 15 Inclined radar sensor locates both targets ..................................................................... 2-14

Figure 16 Digital Inclinometer mounted on radar sensor ............................................................... 2-14

Figure 17 SPx RadarView display (A) ............................................................................................ 2-15

Figure 18 SPx RadarView display (B) ............................................................................................ 2-15

Figure 19 Radar view to locate target ............................................................................................ 2-16

Figure 20 I-200 mounted on a ship to shore container crane. ............................................................. 1

Figure 21 Mounting bracket, and installed on a wall ............................................................................ 1

Figure 22 Two possible methods of mounting a radar centrally, under the boom ............................... 3

List of tables

Table 1 Calculating the installation distance of radar from boom ................................................. 2-6

Table 2 Radar power cable specification .......................................................................................... 1

Table 3 Radar Cat 5E Ethernet cable specification .......................................................................... 1

Table 4 Radar power cable (radar end) connector specification ...................................................... 1

Table 5 Radar Cat 5E cable connector (radar end) specification ..................................................... 3

Installation Guide –I Series iii
Doc ref: MAINT- 0111 Issue 1.2

Referenced Documents

Ref

Title

Supplier

Doc Ref No

1

RadarView-Lite for Windows User
Manual

Cambridge
Pixel

CP-25-127-03

2

SafeGuard witness Commissioning
Guide

Navtech

3

Navtech Service & Maintenance
Manual I-TS Series Radar

Navtech

MAINT 0010
4

SafeGuard witness Operating Guide

Navtech

5

Entry and User Level Firmware
Commands for all W, I and AGS
Series

Navtech

RND – S0069
6

I 200 Datasheet

Navtech

7

Power Supply unit datasheet

Siemens

https://support.automation.siemens.com

6EP1332-1SH52 Data sheet

8

Local Processing Unit Datasheet

Navtech

ANC-0015

9

6 Channel Relay Module

Navtech

ANC-0024

10

Radar power cable assembly

Navtech

SUB-0022

Ref

Drawing No

Title

D1

ASM 0031

Radar Housing

D2

SUB 0119

Inline Power and Serial Cable

D3

MBP 0260

Steel bracket

Referenced Documents

Drawings List

Installation Guide –I Series iv
Doc ref: MAINT- 0111 Issue 1.2

Introduction

1. Introduction

1.1 Scope

The Navtech SafeGuard Detection system provides an automatic monitoring solution for open
areas such as airports, outdoor industrial machines and vehicles that commonly operate in
ports, mines or other industrial areas. The SafeGuard system comprises a high frequency radar
sensor, linked to a software system, witness. This guide provides instruction for the radar
sensor installation ONLY. The installation of the witness application is covered separately in [2].
Service and Maintenance procedures are also covered separately in [3].

The instructions in this guide are applicable to the following Navtech radar sensors:

 I 200
 I 500

Details are provided for all the hardware components required for the installation.

1.2 Essential Items

The following are essential additional items that you need to install a radar sensor:
(i) Electrical Power

Electrical power (110 to 230vAC) sourced from, for example, local mains.

110 to 230vAC power is required for the Radar’s 24vDC PSU.

- 110 to 230vAC power is also required for the Laptop Computer used during the
commissioning process.

Note: Radars are network intensive. Some laptops reduce the performance of their

network connection when only running on their internal battery.

(ii) A way of working safely at height

Most Container Cranes and Bulks Loader have walkways with hand rails - keeping to within the
confines of these hand rails, will keep you relatively safe. However this does depend on the
specific machine or site you are working on. If required to do wear a harness and fall arrestor –
Make sure you clip on to a secure structure or on to a dedicated cable/SWR rope.
Make sure any equipment used conforms to:

 Shock Absorbing Lanyards – EN354/355
 Harnesses – EN361/prEN1496/1497/1498/020895
 Retractable Type Fall Arrester - EN360

Installation Guide –I Series 1-1
Doc ref: MAINT- 0111 Issue 1.2

Introduction

1

(iii) Laptop computer

The laptop should have:

- RJ45 Ethernet connection.

- 9 pin Com port or USB to RS232 adapter [Optional]

- Software – SPxRadarViewLite-V1.47.1 or higher

- Serial communication software – e.g. HyperTerminal, TeraTerm, Putty.

(iv) Cat5E shielded patch lead (or Cross over cable, if laptop doesn’t have Auto-MDIX)
(v) M10 nuts and bolts for mounting radar

The minimum for one radar, in A4 Stainless Steel.

- x4 off M10x80 HEX Set Screw

- x4 off M10 spring washers

- x4 off M10 plain washers

- x4 off Nyloc Nuts

- x12 off M10 Full plain nuts

- x2 off 17mm Spanner for the M10 nuts and bolts above.

(vi) 5m tape measure
(vii) Digital Level1
(viii) 25m² Trihedral Radar Target
(ix) Pair of 2 way radios
(x) An assistant
(xi) Power Supply cable (Minimum Requirement) - see 0Table 2 for specification, or Inline

Radar Power, Serial and Current Cable (Optional) - see [3].

1.3 Pre requisites to working on a Container Crane & Bulk Loaders

Follow local Health and Safety guidelines, as determined by local safety management
procedures. Navtech training courses are available, offering practical advice and
recommendations on how to successfully install and commission the SafeGuard products

Recommended Fisco Solatronic EN17

Installation Guide –I Series 1-2
Doc ref: MAINT- 0111 Issue 1.2

Health & Safety

DC power

Ethernet

Pressure
testing plug

1.4 Radar sensor

The Navtech radar sensor will detect both small and large objects, moving or stationary, within
its line of sight. It is designed to cover 360 degrees, and samples data at an angular resolution
of approximately 0.4 degrees. The radar antenna is designed to have a narrow beamwidth in
azimuth and elevation – typically 1.8 degrees; in this way objects within the radar field of view
can be accurately located on the road surface.

The standard update rate for radar sensors is 120 rpm with a maximum detection distance of
200 meters radius. A signal return is produced and sent to the processing system every 0.25
meters from the sensor itself up to the maximum sensor range of 200 meters radius. This is
repeated at each new azimuth angle as the antenna rotates. The system employs a frequency
modulated sensor and so unlike Doppler systems, no movement is necessary to measure a
vehicle, person or similar object within the radar line of sight.

Figure 1 Radar sensor - isometric views

Installation Guide –I Series 1-1
Doc ref: MAINT- 0111 Issue 1.2

Health & Safety

Figure 2 Radar sensor - dimensions

See [D1] for further details on the radar housing. Each radar is supplied with a Power cable
assembly[10] and an Ethernet environmental shell (which fits over a standard RJ45 to provide
an IP67 seal). Further connector detail in Annex C

Installation Guide –I Series 1-2
Doc ref: MAINT- 0111 Issue 1.2

Health & Safety

2. Installing the Radar hardware

2.1 Overview

This section details the installation process, which comprises the following steps:

1. Determine radar sensor locations

2. Mount radar

3. Connect radar sensor

4. Prepare laptop

5. Connect laptop

6. Level radar sensor

7. Install Navtech witness software

8. Confirm sensor coverage

Note: The installation and configuration of the witness software is covered

separately in [2].

CAUTION Before performing any installation task ensure you are aware of Health &

Safety procedures. (See Section 0)

Installation Guide –I Series 2-3
Doc ref: MAINT- 0111 Issue 1.2

Health & Safety

2.2 Radar sensor locations

2.2.1 Location

Radar sensors must be positioned in such a location that they have optimum ‘line of sight’. To
the objects they are to detect. Both I-200 and I-500 radar sensors scan in a horizontal beam.
The witness processing software is designed to generate an alarm signal, should an object
appear within a detection zone, software configured to lie within the scan area. Other factors to
consider when choosing a mounting location include how close the radar is to a power source
on the machine. Also accessibility, both for installation and on-going maintenance.

Example 1 – Radar installed centrally on the underside of a boom

Below are two diagrams of a radar centrally mounted on the underside of a bulk loader boom.
This mounting location is only suitable if there is no trolley, or loading chute that travels along
the underside of the boom. In this case the installed radar would obstruct the free movement of
the chute

The reason for placing a radar in this location is to detect objects to the side of the boom, which
could be struck if the bulk loaded slewed or long travelled in that direction. A single radar offers
protection on both side of the boom

Figure 3 Single radar mounted on the underside of a bulk loader

Installation Guide –I Series 2-4
Doc ref: MAINT- 0111 Issue 1.2

Health & Safety

Luff Operation - Vertical Radar

Boom length

52

meters

rate of turn on boom Luff

0.15

deg/sec

velocity at the tip of the boom

0.14

meters/sec

Radar detections configured in software processing, to raise a stop alarm

4

Time to detect, for a 2 Hz radar [4Hz option available]

2.0

Sec

Luff meters moved at the boom tip, before full detection

0.27

meters

Safety Margin, to accommodates the boom stopping distance

1.5

meters

The primary use of the single radar scanning a horizontal plane is to protect slew and long travel. A
secondary benefit though, is to stop the boom being lowered/luffed down on to an object that is
raised above the deck level of a vessel. Although, this radar will not detect objects that are beneath
the pane of the horizontal scan, as the boom luffs down these objects should be detected. Care
should be taken to ensure the radar is mounted at a sufficient distance from the underside of the
boom, so the luff motion can be stopped in time to prevent a collision.

By considering the rate of luff of the boom; the scan rate of the radar (typically 2 rps); and the
number of required detections configured in the witness processing software to generate a stop
alarm; the ideal separation between radar and boom can be calculated.

Figure 4 A single radar detects objects as the boom luffs

Installation Guide –I Series 2-5
Doc ref: MAINT- 0111 Issue 1.2