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Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

Page1of7Document No

135278 Rev D

Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to SeaTel, Inc. This document may not be reproduced or distributed in any form without prior writtenconsent of Sea Tel, Inc.

1.

Brief

Summary:

TroubleshootingdocumentfordiagnosingafaultwithandreplacingthePCUassemblyonthe3004,4004,5004&

5004UAantennas.

2.

Checklist:

VerifyInitialization

N0Parameter

PedestalError

TestMotor

3.

Theory

of

Operation:

ThePCUmotherboardcalculatestheamountofmovementfromthevesselbasedonfeedbackfromthesensorsinthe

levelcageanddirectionalchangesfromthevesselsgyrocompasswhicharethenfedintotheantennascontrolloop.The

PCUmotherboardthensendsacommandtothemotordriverPCBtodrivethemotoroftherelevantaxisanequaland

oppositeamountofmovementofthevesseltomaintainstabilizationandcontroltheantennasdishscanpattern.

Alltracking,

targeting,

pointing

and

polarization

commands

are

sent

from

the

DAC

to

the

PCU,

based

on

the

vessels

GPS

location,targetingcalculationsoroperatorinputs.ThePCUinturnthensendsacommandtodrivetherelevantaxis.The

PCUsoftwareconfiguresthefunctionofthepedestalandiscalibratedbytheN0parameter,whichsetsthemotorgains

foreachaxisandthedishscanpatternbasedonthesizeoftheantenna.

ShouldthePCUflagapedestalerror(error8)furtherdiagnosticswillneedtobecompletedtoidentifywhichaxisthe

errorislocatedin,andalsothecomponent(s)whicharepotentiallyfaulty.

4.

Verify

Initialization:

Powercyclethepedestal:

1. Thelevelcagedrivestoitsendstop,andthenturnsto45degrees.

2. Theelevationaxisdrivesto45degreesbasedonthelevelcageshorizonreference(frompreviousstep).

3.

Thecross

level

axis

drives

to

level

based

on

the

level

cages

horizon

reference.

4. Iflimitedazimuththeaxisdrivesclockwiseintotheendstop,thenbackto630degreesofrelative.

5. Theunlimitedazimuthaxisdrivesclockwiseuntilthesensordetectsthehomeflag,thenstopsat0

degreesofrelative.

IftheACUreportsmodel"xx04",thePCUsN0parameterneedscalibrating.RefertothecalibratingthePCUSystem

Parameter(N0)sectionofthisdocument.Failureofanyoftheinitializationstepsorapedestalerrorrequiresfurther

troubleshooting.

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5.

Pedestal

Error

(Error

8):

5.1.

DecodingaPedestalError.

WhentheDACdisplaysapedestalerror,entertheremotecommandwindowandinputS0000thenpress

enter

twice.

The

error

code

will

now

be

displayed

in

the

remote

monitor

screen.

Decode

the

4

th

character

of

theerrorcodefromthebelowtable...

@ None K Ref+LV+CL V StabLimit+AZ+LV

A CL L Ref+AZ W StabLimit+AZ+LV+CL

B LV M Ref+AZ+CL X StabLimit+Ref

C

CL+LV N Ref+AZ+LV Y StabLimit+Ref+CL

D

AZ O Ref+AZ+LV+CL Z StabLimit+Ref+LV

E AZ+CL P StabLimit [ StabLimit+Ref+LV+CL

F

AZ

+

LV

Q

Stab

Limit

+

CL

\

Stab

Limit

+

Ref

+

AZ

G AZ+LV+CL R StabLimit+LV ] StabLimit+Ref+AZ+CL

H Ref S StabLimit+CL+LV ^ StabLimit+Ref+AZ+LV

I Ref+CL T StabLimit+AZ _ StabLimit+Ref+AZ+LV+CL

J Ref+LV U StabLimit+AZ+CL

5.2. ErrorTypes.

The3typesofpedestalerrorare:

1. ServoLimit(CL,LVandAZ)AservolimiterrormeansthePCUmotherboardisissuingthecommand

to

the

motor

driver

PCB/servo

amp

to

drive

the

relevant

axis

harder

than

it

should

under

normal

operation(theservolimithasbeenreached).Thiscouldbewhiletheantennaistryingtomaintainits

pointingangleunderdynamicconditionsorastheantennaisdrivingtheaxistoatargetposition.

2. StabilityLimitAstabilitylimiterrormeanstheantennahasmispointedfromitsdesiredtarget

positionbymorethanhalfadegree.WhenastabilitylimiterrorisflaggedonaVSATantennatheDAC

willsendtheTXMutecommandtoinhibitthetransmitfunctionofthesatellitemodem(itiscommon

toseetheservolimitandstabilitylimiterrorstogether).

3. AZReferenceErrorAnazimuthreferenceerrormeansthereisacorruptreadingintherelativescale.

Thiscouldbecausedbytheencoderfailing,thesystemhittingitsendstopundernormaloperation,or

aphysicalproblemsuchasthebeltslippingonthemotorpulleyorthepulleyslippingonthemotor

shaft.

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5.3. TroubleshootingPedestalErrorsServoLimitandStabilityLimit.

1.

Reinitializethepedestal;doesitdrivecorrectlyornotatall?Ifnoneoftheaxisdrive,verifytheN0and

motorgainparameters(N1=CL,N2=ELandN3=AZ)arecorrectlyconfiguredinthePCUthroughthe

remotecommandwindowoftheDAC.

2. Verifythebalanceoftheantennaandcheckforphysicalrestrictionsonthepedestal.Iftheaxisisnt

correctlybalanced,

the

PCU

will

be

outputting

additional

drive

commands

to

maintain

the

antennas

levelposition.

3.

Isthemotordrivingcorrectlyorisnomotordrivepresent,testthemotorforfaultsusingthebelow

procedure.Ifthemotorisdefectivereplaceitandthenretestthefunctionoftheantenna.Iftheaxisstill

failstodrivecorrectly,thedefectivemotormayhavedamagedthemotordriverPCB.ReplacethePCU

assembly.

4. Anotherpotentialproblemcouldbeadamagedorintermittentharnessconnection.Removethe

harnessbackshellsandverifyallthepinsareseatedcorrectly,checkcontinuityfrompintopinandalso

acrossthepinstoverifythereisnoshortintheconnections.

5.4. TroubleshootingPedestalErrorsAzimuthReferenceError.

1.

Reinitializethe

system

and

verify

that

the

antenna

drives

clockwise

to

its

end

stop

and

then

backs

off

to

630degreesofrelative.

2. Drivetheazimuthaxisin90degreeincrementsandverifythattheantennapointscorrectly,andthat

theDACdisplaysthecorrectrelativeposition.Alsoverifythatthereisnophysicalrestrictiononthe

azimuthaxissuchasthebeltslippingonthemotorpulleyorthepulleyslippingonthemotorshaft.

5.5. TesttheMotor.

1. Checkcontinuitybetweenground(themotorconnectorbackshell)andthe3driveroutputsonpins1,2

and3oftheharness.

2.

Nowcheckcontinuitybetweenpins4,5,6,7and8,andtheground(themotorconnectorbackshell).

3. Checkbetweentheindividualpins1,2and3andtherestofthepins(i.e.testpin1topin4,5,6,7and8

andso

on,

not

between

pins

1and

2,

1and

3or

2and

3).

4. Ifthereisanycontinuitymeasuredonthestepsmentionedabove,themotorisdefective.Ifthemotor

hasdrawnexcessivecurrentthenthereisapossibilitythemotordriverPCB(andpotentiallythePCU

motherboard)hasbeendamaged.Theantennasoperationshouldbeverifiedwithareplacement

motor.Ifafterreplacingthemotortheantennaisstillnotoperational,replacethePCUassemblyasper

thefollowingprocedure.

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6.

Replacing

the

04

Series

PCU

Assembly:

6.1.

Tools.

#2PhillipsScrewdriver

2mmFlat

Blade

(Terminal)

Screwdriver

3/8Socket/Ratchet

Loctite242

6.2. Procedure.

ProcedureforreplacingtheXX04PCUAssembly,SeaTelkitpartNumber:135336(PCUassemblypartnumber:

122203).

*Caution: Powerdownthepedestalbeforefollowingthisprocedure.

1.Usinga#2Phillipsscrewdriver,removethefourscrewsfromthe

sideoftheELpancover,whichattachittotheELpan.

2.Thenremovethesixscrewsfromtheupperandloweredgesofthe

ELpancover.

3.RemovetheELpancoverbyslidingitawayfromthereflector.

4.RemovetheBNCcablefromtheGPSantenna.

5.Then,usinga2mmflatbladescrewdriver,loosentheretaining

screwsoneachoftheharnessDSubconnectorsandunplugall3

connectors.

6.BeingcarefulnottodamagetheGPSpigtailcable,usea3/8

sockettoremovethe3nutssecuringthePCUassemblyinsidetheEL

pan,andremovethePCU.Approachwithcautionastheantennawill

drophardtotherightduetheweightimbalance.

7.InstallthereplacementPCUandsecuretotheELpanusingLoctite

242onallscrews,andReConnecttheDsubconnectorsandBNC

connector.ReinstalltheELpancoverandsecureusingLoctite242

on

all

hardware.

8.ConfigurethePCUsN0parameterandadjustremotetiltsetting.

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7.

Calibrating

the

XX04

Series

PCU

Software

and

N0

parameter:

7.1.

SoftwareRevisions.

TheXX04hasseveralvariations,thestandard3004,4004and5004aswellastheunlimitedazimuth5004

(5004UA)

and

Direct

TV

04

(DTV04).

AsstandardtheXX04seriesPCU(SeaTelpartnumber:122203)isshippedwiththesoftwareversionforthe

3004,4004and5004.IfthereplacementPCUistobeusedona5004UAorDTV04pedestalthesoftware

willneedtobereprogrammedasperthebelowtable.

*Note:Correctattimeofpress,contactyourlocalSeaTelservicedepartmentforthelatestsoftwarerelease.

Model PCUPartNumber SoftwarePartNo SoftwareRevision

XX04 122203 122844 2.53L

XX04UA 1222032 121449 2.53

DTV04 1222033 129951 2.48L

7.2. N0Parameter.

AsPCUsareuniversalacrossthemodelrange,itisnecessarytoconfiguretheN0parameterofthe

replacementPCUtothespecificationofthepedestalitwillbeinstalledon.Thiswillsetthemotorgainsfor

CL(N1),EL(N2)andAZ(N3)andalsoconfigurethedishscanpattern(N7)forthesizeofthepedestals

reflector.

WithouttheN0parameterconfiguredinthePCUtheantennawontinitializeasnoneofthemotorgains

willbeset,onlythelevelcagewilldrive.ThestatuswindowoftheDACwillalsodisplaythemodelnumber

oftheantennaasxx04asopposedto3004,4004or5004.

EnterintotheremotecommandscreenandinputthecorrectN0parameterforthemodelofantenna

asper

the

below

table.

I.e.

the

N0

parameter

for

a4004

is

006

so

enter

N0006

(N0

for

the

systemparameter+006fortheantennamodel).

Savetheremoteparameters.

Cyclepowertothesystemtoreinitializethepedestal,verifyingtheN0hassavedandthesystem

initializescorrectly.

Model

N0

N1

N2

N3

N7

3004 005 024 020 010 029

4004 006 024 024 014 025

5004 007 051 051 021 029

DTV04 004 030 024 014 025

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8.

Calibrating

the

Remote

Tilt

Setting:

Thisprocedureisrequiredtocalibratethelevelcagesothatallthesensorswillbeaccuratelyalignedtotheiraxis.The

fluidfilledtiltsensorprovidesatwodimensionalhorizonreference.Thesystemisnotabletoautomaticallycalculatethe

exactcentervalue,thereforeitisnecessarytoperformthisproceduretomanuallyenteranyoffsetrequiredtomakesure

thePCUreceivesatruehorizonreference.

1. Turndishscanoff:

EnterintotheSetupMenubypressingandholdingthe arrowstogetheruntiltheELTrimorAuto

Trimparameterisdisplayed.

Usethe arrowkeytoscrollthroughthemenuuntilthedishscanwindowisdisplayed.

Pressthe arrowtoactivatethewindowandthenpressthe arrow,followedbythe buttontoturn

dishscanfromontooff.

*Note:Whenyoupressthe arrowtoturndishscanoffyouwontseethedisplaychangeuntilyoupressthe

button.

(Steps27requiresassistancetoobserveandoperateantennasimultaneously)

2. EnterintotheSetupMenubypressingandholdingthe arrowstogetheruntiltheELTrimorAuto

Trimparameterisdisplayed.

3. Pushthe arrowkeyuntiltheRemoteTiltwindowisdisplayed.

4. Pushthe arrowkeytoactivatetheRemoteTiltsetting.

5. Usethearrowkeystopositionthebubbleasclosetothecenteraspossible.Eachpressofanarrowkeyonthe

directionalpadwillmovetheRemoteTilt1/2adegree.Itisadvisedthatyouonlypressthebuttononceandwaitfor

theaxis

to

move

before

pressing

it

again.

Whenstandingbehindtheantennalookingatthebubble,ifthebubbleisovertotheright,youneedtopressthe

(right)arrowtobringthebubbleintothecenter.Ifthebubbleisdowntowardsyou,youneedtopressthe

(down)arrowtobringittowardsthecenter.Ifthebubbleistotheleft,youneedtopressthe (left)arrowandif

thebubbleisuptowardsthetop,youneedpressthe (up)arrowtomoveittowardsthecenter.

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When

correct

the

bubble

should

be

as

close

to

the

center

of

the

fluid

as

possible

6.

Whenthe

bubble

is

as

central

as

possible

press

the

button

to

deactivate

the

Remote

Tilt

setting.

7.

Turndishscanon:

EnterintotheSetupMenubypressingandholdingthe arrowsuntileithertheELTrimorAutoTrim

parameterisdisplayed.

Usethe arrowkeytoscrollthroughthemenuuntilthedishscanwindowisdisplayed.

Pressthe arrowkeytoactivatethewindowandthenpressthe arrowkey,followedbythe buttonto

turndishscanfromofftoon.

*Note:Whenyoupressthe arrowtoturndishscanonyouwontseethedisplaychangeuntilyoupressthe

button.

8. SavetheRemoteTiltsettinginthePCU:

Pressthe arrowkeyuntiltheRemoteParameterswindowisdisplayed.

Pressthe arrowkeytoactivatethewindowfollowedbythe button(youllseeaconfirmationonthe

displaysayingSaved).

9. AsgoodpracticemakeanoteofyourN4andN5parametersonceyouhavecorrectlysettheremotetilt.TheN4and

N5parametersareanumericreadoftheremotetilt.Todothisgototheremotecommandwindowandkeyin

N4999toreadtheCLsetting,followedbyN5999toreadtheELsetting.

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