ASC Signal NGC-ODU-208-3 User manual

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NGC-ODU
Antenna Controller
Unit
&
Handheld Controller
Advanced Technical Manual
Manual# 7580368 – Revision D
ASC Signal Corporation
CANADA: USA:
606 Beech Street 1120 Jupiter Rd.
Whitby, Ontario, Canada Ste. 102
L1N7T8 Plano,TX75074

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© 2010 ASC Signal Corporation
All Rights Reserved. No part of this document may be photocopied, reproduced, stored in a retrieval system, or
transmitted, in any form or by any means whether electronic, mechanical, or otherwise without the prior written
permission of ASC Signal Corporation.
ASC Signal Corporation reserves the right to change details in this publication without notice.
Trademark Notices
Any and all products and companies named herein are the trademarks of their respective creators and/or
owners.
Open Source Software Notice
This product makes extensive use of Open Source Software (OSS), including but not limited to the operating
system, network agents, user interface shells, and tools used to develop the software. This software gives you,
the customer, the benefit of a large base of well-tested and feature-rich system software while lowering the
expense of providing these features to you. It also carries certain obligations.
Some of this software is licensed by the GNU Lesser General Public License (LGPL), which requires that
modifications be kept public but does not require proprietary source code linked to LGPL'ed libraries be made
public. None of this code has been modified for use in this product.
If you have any questions about our interpretation of our obligations under OSS licenses, do not hesitate to
contact us. Our intent is to comply fully with all licensing obligations.
©ASC Signal Corporation
www.ascsignal.com

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TABLE OF CONTENTS
INTRODUCTION: How to Use This Manual 5
I.I Purpose, Overview, & Description 5
I.II Personnel Requirements 6
I.III Miscellaneous Notices 6
I.IV Warning Symbols 6
I.V Safety Terms Summary 7
I.VI Summary of Safety Precautions 7
I.VII THINGS TO NEVER DO 8
I.VIII Parts Verification 8
1.0 Operation of Handheld Controller 9
1.1 Handheld-to-ODU Connection 10
1.2 Handheld Keypad Breakdown 11
1.3 Handheld Screens Breakdown 12
2.0 ODU System & Parts Overview 29
2.1 ODU with Parts Numbered 29
2.2 ODU Connectors & Cable Glands 30
2.3 A1 Master Controller (MC-7) 31
2.4 A2/A4/(OPTION) A6 Axis Control Units (ACU) 34
2.5 A3/A5/(OPTION) A7 Axis Sending Units (ASU) 36
2.6 A8/A9 El/Az VFD 39
2.7 A10 Power Supply Board 42
2.8 Miscellaneous Parts Descriptions 43
2.9 Terminal Blocks (TB1-TB4) 44
2.10 A13 External Wiring Interface (EWI)-1 45
2.11 A13 External Wiring Interface (EWI)-2 47
3.0 ODU System & Parts Troubleshooting 50
3.1 Antenna JOG/Movement Issues 50
3.2 Directional/Axis Issues 53
3.3 Movement & Wiring Troubleshooting Scenarios/Solutions 56
3.4 Polarization Troubleshooting Issues 56
3.5 Other Pol Troubleshooting Scenarios/Solutions 57
3.6 Other Troubleshooting Scenarios 58
4.0 Cleaning, Inspections, & Maintenance 59
4.1 General Cleaning 59
4.2 Inspections 60
4.3 Preservation of Component Parts (Aluminum Only) 60
4.4 Presence of Moisture/Water 61
5.0 NGC-ODU Spare Kits 62
5.1 VFDs 62
5.2 Power Supplies 62
5.3 Boards 62
5.4 Pol Drive Related 62
5.5 Low Temp Related 62
5.6 Circuit Breakers 63
5.7 Spare E-Stop 63
5.8 Spare Handheld Terminal 63
APPENDIX A: PWA Display Codes & NGC-ODU Faults Glossary 64
APPENDIX B: Theory of Operation 67
APPENDIX C: Glossary Tables 73
APPENDIX D: Equipment Issues & Tech Support 89
LIST OF FIGURES
Figure 1-1: Handheld Controller with Connection Cable 9
Figure 1-2: Handheld Keypad 11
Figure 1-3: Handheld Controller Menu/Screen Tree 12

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Figure 1-4a: Home Screen 13
Figure 1-4b: Button Ribbon Options, HOME SCREEN 2 13
Figure 1-4c: Button Ribbon Options, HOME SCREEN 3 13
Figure 1-5: Jog Screen 14
Figure 1-6: GoTo Screen 15
Figure 1-7a: Parameters Screen 16
Figure 1-7b: Parameters Screen (Edit Mode) 17
Figure 1-7c: Button Ribbon Options, Parameters Edit Mode 2 17
Figure 1-8a: Current Faults 18
Figure 1-8b: Button Ribbon Options, Current Faults 2 18
Figure 1-9: Message Log 19
Figure 1-10: Installation Screen 20
Figure 1-11: Diagnostic Commands Screen 21
Figure 1-12a: Password Screen 22
Figure 1-12b: Button Ribbon Options, Password Screen 2 22
Figure 1-12c: Button Ribbon Options, Password Screen 3 22
Figure 1-13: Edit Fraction Screen 23
Figure 1-14a: Search Screen 24
Figure 1-14b: Button Ribbon Options, Search Screen 2 24
Figure 1-14c: Search Screen with Open Dropdown Menu 25
Figure 1-14d: Search Screen with Item Selected 25
Figure 1-15: Voltage Monitor Mask (bitmask edit screen) 27
Figure 1-16: Shortcuts Screen 28
Figure 2-1: NGC Outdoor Unit 29
Figure 2-2: ODU Interface Connectors & Cable Glands 30
Figure 2-3: Master Controller PWA 31
Figure 2-4: Axis Control Unit PWA 34
Figure 2-5: Axis Sending Unit PWA 36
Figure 2-6: VFD (cover off & terminals exposed) 39
Figure 2-7: External Wiring Interface 45
Figure 2-8: EWI-2 board 47
Figure 3.1a: Troubleshooting Flowchart #1a 50
Figure 3.1b: Troubleshooting Flowchart #1b 50
Figure 3.1c: Troubleshooting Flowchart #1c 51
Figure 3.2: Troubleshooting Flowchart #2 51
Figure 3.3: Troubleshooting Flowchart #3 52
Figure 3.4: Troubleshooting Flowchart #4 52
Figure 3.5: Troubleshooting Flowchart #5 53
Figure 3.6: Troubleshooting Flowchart #6 53
Figure 3.7: Troubleshooting Flowchart #7 54
Figure 3.8: Troubleshooting Flowchart #8 54
Figure 3.9: Troubleshooting Flowchart #9 55
Figure 3.10: Troubleshooting Flowchart #10 55
Figure 3.11: Troubleshooting Flowchart #11 56
Figure 3.12: Pol Troubleshooting Flowchart #1 56
Figure 3.13: Pol Troubleshooting Flowchart #2 57
Figure 3.14: Pol Troubleshooting Flowchart #3 57
Figure B-1: NGC-ODU Block Diagram 67
Figure B-2: NGC Antenna Control System Block Diagram 68
LIST OF TABLES
Section 1.0
1.1: Important Screen Icons 12
Section 2.0
2.1: NGC Outdoor Unit Parts List 30
2.2: ODU Connectors & Cable Glands 31
2.3: MC-7 PWA Front Edge Indicator LEDs and Display 32
2.4: MC-7 PWA Indicator LEDs Description 32
2.5: MC-7 Jacks & Plugs 33
2.6: MC-7 Switches 33
2.7: MC-7 Jumpers 33
2.8: MC-7 Test Points 33
2.9: Axis Control Unit PWA Front Edge Indicator LEDs & Display 34
2.10: Axis Control Unit PWA Indicator LEDs Description 35
2.11: ACU Jacks & Plugs 35

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2.12: ACU Switches 35
2.13: ACU Jumpers 35
2.14: ACU Test Points 36
2.15: Axis Sending Unit PWA Front Edge Indicator LEDs & Display 37
2.16: Axis Sending Unit PWA Indicator LEDs Description 37
2.17: ASU Jacks & Plugs 38
2.18: ASU Switches 38
2.19: ASU Jumpers 38
2.20: ASU Test Points 38
2.21: ASU Potentiometers 38
2.22: VFD Sizes 40
2.23: VFD Terminals Descriptions 40
2.24: VFD Parameters (208VAC & 380VAC) 41
2.25: A10 P/Ns & Specifications 43
2.26: NGC Bus Cable Pin-Out 44
2.27: TB4 Designations 44
2.28: TB3 Designations 44
2.29: TB2 Designations 45
2.30: TB1 Designations 45
2.31: EWI-1 Connectors 45
2.32: EWI-1 J1/J4/J6 Pin-out 46
2.33: EWI-1 J2/J5 Pin-out 46
2.34: EWI-1 J3 Pin-out 46
2.35: EWI-1 J5 Pin-out 46
2.36: EWI-1 J7 Pin-out 47
2.37: EWI-2 Connectors 48
2.38: EW2-1 J6 Pin-out 48
2.39: EWI-2 J2/J5 Pin-out 48
2.40: EWI-2 J3 Pin-out 49
2.41: EWI-2 J5 Pin-out 49
2.42: EW2-1 J6 Pin-out 49
2.43: EWI-2 J7 Pin-out 49
Appendices
A.1: Error Codes 64
A.2: Faults Glossary 65
C.1: List of Handheld Terminal Parameters 73
C.2: Encoder/Resolver Types 81
C.3: Axis Limit Conditions, Azimuth, Polarization, & SRT X axes 81
C.4: Axis Limit Conditions, Elevation & SRT Y axes 81
C.5: Supplementary azimuth axis inputs 82
C.6: Supplementary elevation axis inputs 82
C.7: Cabinet power status fields 82
C.8: NGC Communications Bus Entities 82
C.9: Compass Calibration Statuses 82
C.10: Compass Faults 83
C.11: Compass Mode 83
C.12: GPS Faults 83
C.13: GPS Quality 83
C.14: Limit Switch Mask Fields 83
C.15: Local Remote settings 84
C.16: Axis Movement Faults 84
C.17: Movement command enumerations 84
C.18: Voltage Monitor Mask values 85
C.19: Operational Configurations 85
C.20: Stepper Motor types 85
C.21: Polarization Axis Setup 85
C.22: SRT Axes Present field 85
C.23: SRT Movement Command 86
C.24: SRT Overall Status 86
C.25: SRT Temperature Status 86
C.26: SRT Z Limit status field 86
C.27: Track Mode enumeration 87
C.28: Track State field meanings 87
C.29: VFD DataLink Status 87
C.30: Diagnostic Commands 88

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INTRODUCTION: How to Use This Manual
I.I Purpose, Overview, & Description
The purpose of this manual is to provide preventive maintenance, troubleshooting and corrective maintenance information
together with detailed checkout procedures for the NGC Antenna Controller Outdoor Unit (ODU). This manual is
intended for use by qualified technical and/or installation personnel ONLY, for the performance of installation,
operation, and maintenance procedures for the NGC-ODU system.
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Overview
This technical manual contains information for NGC Antenna Controller Unit, Outdoor Unit for Receive/Transmit
Antennas. The basic equipment and accessories are either manufactured or design controlled by ASC Signal Corporation.
The manual contains recommended procedures to be performed by qualified technical personnel.
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General Product Description
The ASC Signal Corporation, NGC Antenna Controller Outdoor Unit Models, all of which are designed to be used with
ASC Signal motorizable fixed antennas:
NGC-ODU-208-3 NGC-ODU-208-3-HA
NGC-ODU-208-5 NGC-ODU-208-5-HA
NGC-ODU-380-3 NGC-ODU-380-3-HA
NGC-ODU-380-5 NGC-ODU-380-5-HA
The ASC Signal NGC is a modular, scalable, adaptable advanced-level antenna pointing and tracking controller intended
for motorized satellite earth station antennas used with geosynchronous communications satellites.
The system is intended for new installations, and as a replacement for legacy control systems such as the ASC Signal
APC100, APC400, and ACS3000 systems.
The NGC provides the following basic and optional features:
Variable Speed motor control for two- and three-axis motor systems complying with the standard ASC Signal
interface, using VFDs for driving the azimuth and elevation axes.
Support for single phase AC polarization rotators.
Automatic positioning of antennas to pre-programmed look angles.
Optical Interfacility link
Local control from the indoor unit through an advanced touch panel LCD and keypad.
Local control from the outdoor unit through an advanced handheld unit
Automatic installation commissioning assistance
10/100 BaseT Ethernet interface for external M&Cs (via the IDU)
Remote control through network-based and serial-port-based communications protocols, including both legacy
protocols and SNMP.
Integral beacon receiver interfaces to support ASC Signal’s patented three-point peaking step-track and
SmarTrack® hybrid feedback/predictive program tracking algorithms.
NORAD and Intelsat program tracking
Optional integrated subreflector tracking (SRT) capability for high-accuracy Ka-band tracking, including hybrid
main dish and SRT positioning and tracking
The NGC is physically divided into an Indoor Unit (NGC-IDU) and an Outdoor Unit (NGC-ODU), connected by a dedicated
multimode optical fiber link. The NGC-IDU is a 3RU 19-inch rackmount chassis that is mounted inside the equipment
shelter or building. It provides the user interface and the interface to the tracking receivers. All NGC variants have the
same NGC-IDU package.
The NGC-ODU is packaged in multiple layouts based on application. All are generally mounted outside, on the positioned,
pedestal or tripod mount. Depending on the ordered chassis variant, the NGC-ODU may use 208VAC or 380VAC three-
phase wye power, or 230VAC single-phase power. The NGC-ODU may use common or separate sources for technical
and service power, as desired by the customer.
The functional allocation between NGC-IDU and NGU-ODU follows one basic principle: the indoor unit generates all
pointing commands and the outdoor unit executes them. All tracking functions are isolated to the NGC-IDU, which as
mentioned is indoors, where the beacon receiver or other signal measurement device will be located. All motion control
functions are isolated to the NGC-ODU, which is located on the positioner or pedestal, allowing the termination of all local
control cables after short runs and minimizing the interconnection between indoor and outdoor to AC power, transmit and
receive signals, and a single control fiber.

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Unlike many previous systems, pointing commands from the NGC-IDU to the NGC-ODU are always given in horizon-
oriented coordinates (that is, true azimuth and true elevation). The NGC-ODU software performs all necessary coordinate
transformations to determine “local” azimuth and elevation position commands, and to provide feedback in both local and
horizon-oriented coordinate frames.
No configuration of the dedicated link between NGC-IDU and NGC-ODU is required. This avoids the need for the installer
to understand TCP/IP networking configuration.
I.II Personnel Requirements NOTICE
THE INSTALLATION, MAINTENANCE OR REMOVAL OF AN ANTENNA REQUIRES QUALIFIED,
EXPERIENCED PERSONNEL.
ASC SIGNAL CORP. INSTALLATION INSTRUCTIONS HAVE BEEN WRITTEN AND ILLUSTRATED FOR SUCH
PERSONNEL.
ANTENNA SYSTEMS SHOULD BE INSPECTED AT LEAST ONCE A YEAR BY QUALIFIED PERSONNEL TO
VERIFY PROPER INSTALLATION, MAINTENANCE AND CONDITION OF THE EQUIPMENT.
ASC SIGNAL CORP DISCLAIMS ANY LIABILITY OR RESPONSIBILITY FOR THE RESULT OF IMPROPER OR
UNSAFE INSTALLATION OR MAINTENANCE PRACTICES.
I.III Miscellaneous Notices
Proprietary Information
The technical data contained herein is proprietary to ASC Signal Corporation. It is intended for use in the installation,
operation, and maintenance of ASC Signal equipment. This data shall not be disclosed or duplicated, in whole or in part,
without the expressed written consent of ASC Signal Corporation.
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Installation Notice
Installation, maintenance, or removal of the hardware described in this manual requires qualified and experienced
personnel. ASC Signal installation instructions are written for such personnel. Qualified personnel MUST perform
proper installation and maintenance of the equipment, and MUST verify the condition of the equipment at initial
installation and periodically thereafter.
NOTE: ASC Signal is NOT liable or responsible for results of improper or unsafe installation and maintenance practices.
All designs, specifications, and availability of products are subject to change without notice.
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IMPORTANT: What to Know When You See OPTION:
Any time you see OPTION:, this means that the information following it is related to an optional element (in either
hardware or software) that may or may not apply to the arrangement of your particular NGC Unit. Please note that if you
see an option that you do not have but would like to purchase, please contact ASC Signal.
I.IV Warning Symbols
Various components of this System may display safety symbols. Be sure to use extreme caution when operating
components with any of the following safety symbols:
Certains éléments du système montreront peut-être des symboles de sécurité. Faites très attention à faire marcher tous
les éléments qui tiennent les symboles de sécurité suivants:
OR WARNING! HAZARDOUS MOVING PARTS! KEEP FINGERS AND OTHER BODY PARTS AWAY!
AVERTISSEMENT! PIÈCES MOBILES DANGEREUSES! GARDEZ LES DOIGTS ET LES AUTRES PARTIES DU
CORPS HORS D’ATTEINTE!
WARNING! RISK OF ELECTRIC SHOCK!
AVERTISSEMENT! RISQUE D’ÉLECTROCUTION!
WARNING! REFER TO MANUAL
AVERTISSEMENT! SE RÉFÉRER AU MANUEL D’UTILISATION.

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I.V Safety Terms Summary
The following safety terms may appear on the product:
Les termes de sécurité suivants peuvent apparaître sur le produit:
DANGER—Indicates an immediately accessible injury hazard is present as you read the marking, and failure to take
precautions could result in loss of life
DANGER—Cette indication signale un risque de blessure immédiat et qui peut être mortel.
WARNING—Indicates a nearby injury hazard that is not immediately accessible as you read the markings, and failure to
take precautions could result in personal injury and/or loss of life
AVERTISSEMENT—Cette indication signale un risque de blessure non immédiat mais qui peut être mortel.
CAUTION—Indicates a potential hazard to property, including the product
PRUDENCE—Indique un risque pour l’environ du produit, le produit inclus.
The following safety symbols and terms may be used in this manual:
Les symbols et les termes suivants de sûreté peuvant être employés en ce manuel:
WARNING! Statements identify conditions & practices that could result in injury or loss of life.
AVERTISSEMENT! Les rapports d’avertissement identifient les conditions ou les pratiques qui pourraient avoir comme
conséquence les dommages ou la perte de la vie.
RISK OF ELECTRIC SHOCK!
RISQUE DE DÉCHARGE ÉLECTRIQUE!
I.VI Summary of Safety Precautions
The following safety precautions are not related to any specific procedure, and so will not appear elsewhere in this
manual. Ensure all personnel understand & apply these precautions in all phases of installation, operation, &
maintenance. Failure to do so may result in loss of life.
KEEP AWAY FROM LIVE CIRCUITS: Personnel must observe all applicable safety regulations at all times. Ensure
power is disconnected or removed from the unit BEFORE replacing any components. Potential hazards may exist even
though the power control switch is in OFF position. Capacitors retain electrical charges. Always REMOVE POWER & use
test equipment to confirm a circuit is at ground potential BEFORE touching it. NEVER reach into or enter an enclosure to
service or adjust the equipment until the absence of power has been confirmed.
DO NOT SERVICE OR ADJUST ALONE: Under NO circumstances should ANY person reach into or enter the
enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable
of rendering aid in case of an accident/emergency.
RESUSCITATION: Personnel working with or near high voltage should be familiar with resuscitation methods (CPR
and/or AED). CPR info may be obtained from medical personnel. For AED (Automated External Defibrillator) information,
contact supervisor or hosting administration for details on the availability and/or location of an AED unit at your worksite.
ELECTROSTATIC DISCHARGE PRECAUTION
This equipment contains electrostatic discharge (ESD) sensitive devices. ESD sensitive equipment handling methods
must be used to prevent equipment damage during handling and servicing.
ESSENTIAL HEALTH AND SAFETY REQUIREMENT
Refer to document “P/N 240117—Essential Health and Safety Requirements”.

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I.VII THINGS TO NEVER DO
NEVER touch circuits or reach into an enclosure until the disconnection of power and absence of charge has been
confirmed
NEVER service or adjust equipment alone. Electric shock can lead to cardiac arrest. Presence of immediate aid gives
you a 90% chance of survival, but this drops by 10% with every passing minute. After 5 minutes, resuscitation
without permanent heart and/or brain damage is nearly impossible. Consider this: Without the immediate aid of
CPR or an AED, what are the odds you will be found and successfully revived in under 5 minutes?
NEVER ignore warning symbols or fail to read safety signs
NEVER skip steps in a sequence, unless specifically instructed to do so by the manual, software, and/or authorized
ASC Tech Support Personnel. Aside from risking harm to yourself, you risk doing permanent damage to the equipment
NEVER touch or stand near any potentially moving parts (even if they are not in motion at the time) when the unit is in
operation or powered on, as they may move without warning
NEVER stand underneath any object while it is being lifted
NEVER remove, disable, or exceed the unit’s safety, software, security, or movement limits, unless specifically
instructed to do so by the manual, software, and/or authorized ASC Tech Support Personnel. The careless disabling of
such safeguards is one of the most common causes of serious equipment damage during installation and operation
I.VIII Parts Verification
STOP! READ BEFORE BEGINNING ASSEMBLY OR INSTALLATION!
Upon receipt of your order, the shipment should be verified to ensure that all parts have reached your site. This process
should occur before the installation process begins. ASC Signal Corporation thoroughly inspects and carefully packs all
equipment before shipment. If you find that there are missing or damaged components, please refer to the step-by-step
instructions (located in back of this manual) on how to properly report equipment loss or damage. When you have
received your order, verify that all parts contained in the shipment correspond to the parts listed on your packing
slip/inventory.

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1.0 Operation of Handheld Controller
The NGC-ODU may be controlled from the pedestal base, via use of the Handheld Controller (shown below in
Figure 1-1).
Figure 1-1: Handheld Controller with Connection Cable
The Handheld Controller is QTERM-G55 model controller with a 320x240 pixel, LCD transflective FSTN,
grayscale (16 shades) display. The display screen employs a light emitting diode (LED) backlight. The LED
provides excellent readability under most lighting conditions and can operate in either portrait or landscape
mode. The FSTN contrast is software-controlled and compensated for temperature. The transflective display
provides excellent sunlight or high ambient light readability. The backlight also provides white lighting for high
contrast and easy readability. Brightness of the backlight and FSTN contrast are controlled by software. User
input occurs through a rugged 24-key membrane keypad with steel domes. This 24-key keypad allows for
function/soft keys, four-way directional control and alphanumeric data entry. Certain keys can perform alternate
functions when the shift key is enabled (refer to Table below Figure 1-2 for specifics).
Setup parameters are password protected in the handheld terminal and can only be accessed by logging
into the handheld. In most cases, the handheld terminal will be shipped with the Persistent Password
already logged in. If the handheld terminal requests that you login, use one of passwords listed below.
The “Temporary” password will automatically logout when power to the handheld is disconnected. The
“Persistent” password will keep the handheld logged in until the user forces it to logout. You will need the
following passwords to access the system:
ODU/Handheld TEMPORARY Installer Password:JFQB23
ODU/Handheld PERSISTENT Admin Password:32BQFJ
The handheld terminal’s LCD screen is a backlit graphical interface. The LCD displays messages to
indicate the antenna functions and status. Antenna functions and status include whether or not the
antenna is moving, if a satellite signal is found, if a signal is lost, etc. The LCD indicates soft key
functions on a given screen. Additionally, the LCD alerts you if a system fault occurs, and allows you to
troubleshoot the antenna.