Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

1. BriefSummary:
TroubleshootingdocumentfordiagnosingafaultwithandreplacingthePCUassemblyonthe3004,4004,5004&
5004UAantennas.
2. Checklist:

VerifyInitialization
N0Parameter
PedestalError
TestMotor
3. TheoryofOperation:
ThePCUmotherboardcalculatestheamountofmovementfromthevesselbasedonfeedbackfromthesensorsinthe
levelcageanddirectionalchangesfromthevesselsgyrocompasswhicharethenfedintotheantennascontrolloop.The
PCUmotherboardthensendsacommandtothemotordriverPCBtodrivethemotoroftherelevantaxisanequaland
oppositeamountofmovementofthevesseltomaintainstabilizationandcontroltheantennasdishscanpattern.
Alltracking,targeting,pointingandpolarizationcommandsaresentfromtheDACtothePCU,basedonthevesselsGPS
location,targetingcalculationsoroperatorinputs.ThePCUinturnthensendsacommandtodrivetherelevantaxis.The
PCUsoftwareconfiguresthefunctionofthepedestalandiscalibratedbytheN0parameter,whichsetsthemotorgains
foreachaxisandthedishscanpatternbasedonthesizeoftheantenna.
ShouldthePCUflagapedestalerror(error8)furtherdiagnosticswillneedtobecompletedtoidentifywhichaxisthe
errorislocatedin,andalsothecomponent(s)whicharepotentiallyfaulty.
4. VerifyInitialization:

Powercyclethepedestal:
1. Thelevelcagedrivestoitsendstop,andthenturnsto45degrees.
2. Theelevationaxisdrivesto45degreesbasedonthelevelcageshorizonreference(frompreviousstep).
3. Thecrosslevelaxisdrivestolevelbasedonthelevelcageshorizonreference.
4. Iflimitedazimuththeaxisdrivesclockwiseintotheendstop,thenbackto630degreesofrelative.
5. Theunlimitedazimuthaxisdrivesclockwiseuntilthesensordetectsthehomeflag,thenstopsat0
degreesofrelative.

IftheACUreportsmodel"xx04",thePCUsN0parameterneedscalibrating.RefertothecalibratingthePCUSystem
Parameter(N0)sectionofthisdocument.Failureofanyoftheinitializationstepsorapedestalerrorrequiresfurther
troubleshooting.
Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

5. PedestalError(Error8):
5.1. DecodingaPedestalError.
WhentheDACdisplaysapedestalerror,entertheremotecommandwindowandinputS0000thenpress
entertwice.Theerrorcodewillnowbedisplayedintheremotemonitorscreen.Decodethe4
th
characterof
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 StabLimit+CL \ StabLimit+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
tothemotordriverPCB/servoamptodrivetherelevantaxisharderthanitshouldundernormal
operation(theservolimithasbeenreached).Thiscouldbewhiletheantennaistryingtomaintainits
pointingangleunderdynamicconditionsorastheantennaisdrivingtheaxistoatargetposition.
2. StabilityLimitAstabilitylimiterrormeanstheantennahasmispointedfromitsdesiredtarget
positionbymorethanhalfadegree.WhenastabilitylimiterrorisflaggedonaVSATantennatheDAC
willsendtheTXMutecommandtoinhibitthetransmitfunctionofthesatellitemodem(itiscommon
toseetheservolimitandstabilitylimiterrorstogether).
3. AZReferenceErrorAnazimuthreferenceerrormeansthereisacorruptreadingintherelativescale.
Thiscouldbecausedbytheencoderfailing,thesystemhittingitsendstopundernormaloperation,or
aphysicalproblemsuchasthebeltslippingonthemotorpulleyorthepulleyslippingonthemotor
shaft.

Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

5.3. TroubleshootingPedestalErrorsServoLimitandStabilityLimit.
1. Reinitializethepedestal;doesitdrivecorrectlyornotatall?Ifnoneoftheaxisdrive,verifytheN0and
motorgainparameters(N1=CL,N2=ELandN3=AZ)arecorrectlyconfiguredinthePCUthroughthe
remotecommandwindowoftheDAC.
2. Verifythebalanceoftheantennaandcheckforphysicalrestrictionsonthepedestal.Iftheaxisisnt
correctlybalanced,thePCUwillbeoutputtingadditionaldrivecommandstomaintaintheantennas
levelposition.
3. Isthemotordrivingcorrectlyorisnomotordrivepresent,testthemotorforfaultsusingthebelow
procedure.Ifthemotorisdefectivereplaceitandthenretestthefunctionoftheantenna.Iftheaxisstill
failstodrivecorrectly,thedefectivemotormayhavedamagedthemotordriverPCB.ReplacethePCU
assembly.
4. Anotherpotentialproblemcouldbeadamagedorintermittentharnessconnection.Removethe
harnessbackshellsandverifyallthepinsareseatedcorrectly,checkcontinuityfrompintopinandalso
acrossthepinstoverifythereisnoshortintheconnections.

5.4. TroubleshootingPedestalErrorsAzimuthReferenceError.
1. Reinitializethesystemandverifythattheantennadrivesclockwisetoitsendstopandthenbacksoffto
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
andsoon,notbetweenpins1and2,1and3or2and3).
4. Ifthereisanycontinuitymeasuredonthestepsmentionedabove,themotorisdefective.Ifthemotor
hasdrawnexcessivecurrentthenthereisapossibilitythemotordriverPCB(andpotentiallythePCU
motherboard)hasbeendamaged.Theantennasoperationshouldbeverifiedwithareplacement
motor.Ifafterreplacingthemotortheantennaisstillnotoperational,replacethePCUassemblyasper
thefollowingprocedure.

Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

6. Replacingthe04SeriesPCUAssembly:
6.1. Tools.

#2PhillipsScrewdriver
2mmFlatBlade(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
onallhardware.

8.ConfigurethePCUsN0parameterandadjustremotetiltsetting.

Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

7. CalibratingtheXX04SeriesPCUSoftwareandN0parameter:
7.1. SoftwareRevisions.
TheXX04hasseveralvariations,thestandard3004,4004and5004aswellastheunlimitedazimuth5004
(5004UA)andDirectTV04(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
asperthebelowtable.I.e.theN0parameterfora4004is006soenterN0006(N0forthe
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

Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

8. CalibratingtheRemoteTiltSetting:
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
theaxistomovebeforepressingitagain.
Whenstandingbehindtheantennalookingatthebubble,ifthebubbleisovertotheright,youneedtopressthe
(right)arrowtobringthebubbleintothecenter.Ifthebubbleisdowntowardsyou,youneedtopressthe
(down)arrowtobringittowardsthecenter.Ifthebubbleistotheleft,youneedtopressthe (left)arrowandif
thebubbleisuptowardsthetop,youneedpressthe (up)arrowtomoveittowardsthecenter.

Field Service Procedure - Replacement PCU Kit, XX04 & XX04UA

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Document No
135278 Rev D
Copyright Sea Tel, Inc 2011 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc.

Whencorrectthebubbleshouldbeasclosetothecenterofthefluidaspossible

6. Whenthebubbleisascentralaspossiblepressthe buttontodeactivatetheRemoteTiltsetting.

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.