Dawn CONTROL-1500A User manual

Inclined-Orbit tracking
Allows single axis tracking for modest-sized
antennas with a motorized declination axis
Three Track Modes
Step Track, Memory & Search modes
supported
Polarization Control Interface
Automatic or manual polarization control for
three-wire PolarotorTM or optional control for
rotating feeds with potentiometer feedback
High-Resolution Pulse Sensor Interface
Ensures accurate Ku-band positioning
Software Controlled Limits
Provides backup to mechanical limits
Dual Speed
For fast slewing, fine positioning, user
programmable
RS-422 PC Control Interface
Automated control with many popular
packages; basic PC-control software is
included
Adapti-DriveTM
Maintains stable speed with varying load
Solid-State Drive Circuitry
Provides reliable, quiet operation, rated at 5A
with over-current protection
Multi-Band Operation
Supports C, Ku and L-band satellites
F E A T URE S
Re m o t e Co n trolle d
A n t e n n a Co n t roller
for S i n gle A x is A n t e n n as
CONTROL-1500A (Specs pg1-2, Manual on pg3)
3340 S. Lapeer Rd Orion, MI 48359-1320 Ph [phone] Fax [phone] [e-mail]
You are entitled to the manufacturer's limited express warranty, if any, that accompanies the product. DAWNco
makes no additional or independent warranty.
All other warranties, express or implied, including the warranties of merchantability and fifitness for a particular
purpose are disclaimed. We do our best to be accurate.
We are not responsible for any typographical, photographic or technical errors. See "Policies for DAWNco" under
the "Answers" button at the DAWNco web site.

PHYSICALPHYSICAL
Size:Size: 19.0”x 3.5”x 9.0” ( rack )
Weight:Weight: 8.5 lbs.
Temperature:Temperature: 0o – 50oC
Input Power:Input Power: 115/230 V AC,50/60 Hz., 40 W
determined by antenna beamwidth (as determined from antenna
size and the frequency band), satellite inclination, and a user
specified maximum allowable error (in dB). STEP_TRACK mode
is active until a time is reached that corresponds to a segment of
the satellite's motion which has previously been stored in the track
table. When this occurs PROGRAM_TRACK mode is activated.
In PROGRAM_TRACK mode the controller smoothly moves the
antenna to azimuth and elevation positions derived from entries in
the track table. The time between movements is determined by
the same factors which govern the time between peakup
operations in STEP_TRACK mode. In particular the user can
specify the maximum allowable error between the antenna's actual
position and the position specified by the track table. By
increasing the maximum allowable error, antenna movements can
be performed less frequently, thus avoiding unnecessary wear on
the antenna actuators. In PROGRAM_TRACK mode the accuracy
of the track table is monitored by periodically peaking up the
receiver AGC signal. If the error exceeds a level set by the user,
all entries in the track table are flagged for update. The period
between these accuracy checks is specified by the user and
typically varies from once a day to once a week.
SEARCH mode is entered from STEP_TRACK mode when the
satellite signal has been lost. When the satellite is located, the
controller re-enters the STEP_TRACK mode.
TRACK MODETRACK MODE
Antenna Size:Antenna Size: 0.4 – 5.0 meters
Maximum InclinMaximum Inclina-a- +/-10ostandard
Tracking Modes:Tracking Modes: S earch, S tep Track,Program
Track
AGC Input:AGC Input: 0 to +10 VDC inputrange,2MΩ
inputimpedance
When using a modest-sized antenna in which the beam may be
steered along the declination axis, (perpendicular to the
geostationary arc) a satellite that is in an inclined orbit may be
tracked with a single-axis antenna controller. The angular width of
the “figure 8” pattern of the satellite’s apparent motion is, in
general, very small. For the mid-latitudes, this width is
approximately:
W = 1.2 x (inclination)2/ 115
or 0.26 degrees for a satellite with an inclination of 5 degrees.
If the antenna beamwidth is larger than the width of the figure 8, it
can track the satellite with single-axis, declination motion. An
11.5m C-band or an 3.8m Ku-band antenna would have a 3dB
beamwidths of about 0.6 degree. Properly aligned, these
antennas could track the satellite with less than 3dB error.
The tracking algorithm used by the RC2000 antenna controllers
can be divided into 3 distinct parts - STEP_TRACK,
PROGRAM_TRACK and SEARCH. To initiate the track process,
the user jogs the antenna to the satellite and verifies the identity of
the satellite. The system then enters STEP_TRACK mode.
In STEP_TRACK mode, the controller periodically peaks the
receiver's AGC signal strength by jogging the antenna. The time
and position are recorded in a track table maintained in the
controller’s non-volatile memory. The interval between peakups is
O P E R A TI O N A L O V E R V I E W
The RC1500 was designed to provide years of reliable operation
through the use of a heavy duty solid-state drive network coupled
with a novel microcontroller-based fault monitoring system. The 5
amp rated drive output capability is adequate for either moving
feed trackers or full-size linear actuators and the Adapti-Drive
digital servo speed control optimizes antenna movement for
today's demanding Ku-band applications. Additional features like
an RS-422 communications port for PC control and a very user-
friendly, menu scheme make the RC1500 a unique and highly
adaptable piece of equipment. Overall, the RC1500 is well
equipped to handle the demanding requirements for cost sensitive
domestic and international inclined-orbit satellite tracking.
T R A C K I N G A L G O RI T H M
S P E CI F I C A T I O N S
DRIVEDRIVE
Output:Output: 36 VDC,10 Amps;150 VA
Sensor Input:Sensor Input: Pulse-type: R eed,Hall Effect,Optical
Polarization:Polarization: S tandard PolarotorTM Interface,
optionalrotating Feed-drive at
voltagesfrom 5 – 36 VDC @2A max
3340 S. Lapeer Rd Orion, MI 48359-1320 Ph [phone] Fax [phone] [e-mail]
You are entitled to the manufacturer's limited express warranty, if any, that accompanies the product. DAWNco
makes no additional or independent warranty.
All other warranties, express or implied, including the warranties of merchantability and fifitness for a particular
purpose are disclaimed. We do our best to be accurate.
We are not responsible for any typographical, photographic or technical errors. See "Policies for DAWNco" under
the "Answers" button at the DAWNco web site.

CONTROL-1500ASingle Axis
Antenna Controller
Operator's Manual
v1.20
CONTENTS SUBJECT TO CHANGE
Jan29,2004
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]
You are entitled to the manufacturer's limited express warranty, if any, that accompanies the product. DAWNco makes no
additional or independent warranty. All other warranties, express or implied, including the warranties of merchantability and
fitness for a particular purpose are disclaimed. We do our best to be accurate. We are not responsible for any typographical,
photographic or technical errors. See "Policies for DAWNco" under the "Answers" button at the DAWNco web site.

TABLE OF CONTENTS
Warranty.....................................................................................................................................6
Chapter 1 INTRODUCTION ...................................................................................................1
1.1 Organization of this Manual.............................................................................................1
1.2 Before You Begin ............................................................................................................2
Chapter 2 BASIC FUNCTION DESCRIPTION.......................................................................3
2.1 Front Panel......................................................................................................................3
2.2 Changing Modes with the MODE Key .............................................................................5
2.3 Mode Descriptions...........................................................................................................5
2.4 Mode Access...................................................................................................................9
2.5 Expert Access................................................................................................................10
2.6 AutoPol..........................................................................................................................10
Chapter 3 INSTALLATION/SETUP ......................................................................................11
3.1 Before You Begin ..........................................................................................................11
3.2 Mechanical and Electrical Installation............................................................................12
3.2.1 Antenna Motor Drive ...............................................................................................13
3.2.2 Position Sense .........................................................................................................14
3.3 Polarization Control .......................................................................................................17
3.3.1 Configuring the CONTROL-1500Afor Use inan Installation that Does Not Employ a
Polarization Control Device...............................................................................................17
3.3.2 Configuring the RC1500 for use with a Polarotor....................................................17
3.3.3 Rotating Feed with Potentiometer Position Feedback.............................................18
3.4 Antenna Drive Polarity and Limits..................................................................................21
3.4.1 Motor Drive Polarity................................................................................................22
3.4.2 Setting Antenna Limits ...........................................................................................22
3.4.3 Polar Mount Adjustment .........................................................................................22
3.5 Slow Speed Adjustment ................................................................................................25
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]

3.6 Signal Strength Display .................................................................................................26
3.6.1 Controller AGC Potentiometor Adjustment..............................................................27
3.7 Programming Geostationary Satellites ..........................................................................32
3.8 AutoPol..........................................................................................................................33
3.9 Installation and Setup Checklist.....................................................................................34
Chapter 4 – Controller Operational and Programming Modes .................................................36
4.1 MANUAL Mode..............................................................................................................36
4.2 AUTO Mode ..................................................................................................................37
4.2.1 Invalid Data .............................................................................................................38
4.3 REMOTE Mode .............................................................................................................39
4.4 LIMITS Mode.................................................................................................................39
4.5 SETUP Mode.................................................................................................................40
4.5.1 User-Defined Satellite Names.................................................................................42
4.6 RESET Mode.................................................................................................................43
4.7 DELETE Mode...............................................................................................................44
4.8 FIX Mode.......................................................................................................................45
4.9 CONFIG Mode...............................................................................................................45
4.9.1 AutoPol.................................................................................................................46
4.9.2 Remote Communication Parameters ...................................................................46
4.9.3 Slow Speed Code ................................................................................................47
4.9.4 Polarization Motor Option.....................................................................................47
4.9.5 Motor Drive Options .............................................................................................48
4.9.6 Signal Strength Parameters .................................................................................50
4.9.7 Expert Access Flag ..............................................................................................50
4.9.8 Reset System Data ..............................................................................................51
Chapter 5 SPECIFICATIONS...................................................................................................53
Chapter 6 TROUBLESHOOTING/ALARM CODES ................................................................54
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]

6.1 SYSTEM ERROR CODES ............................................................................................54
LOW BATTERY ................................................................................................................54
ANT LIMITS ......................................................................................................................54
POL LIMITS ......................................................................................................................54
ANT AZ/EL, ANT POL.......................................................................................................55
AZ/EL COUNT ..................................................................................................................55
SLOW SPEED ..................................................................................................................55
AUTOPOL CFG ................................................................................................................55
COMM PORT....................................................................................................................55
POL OPTIONS..................................................................................................................55
AZ/EL OPTIONS...............................................................................................................55
6.2 OPERATIONAL TROUBLESHOOTING TIPS ...............................................................55
Appendix A Expert Access and System Reset Code ..............................................................58
Appendix A1 - Restoring Non-Volatile Memory ........................................................................59
Appendix A2 - Recovering From Unexpected Memory Upsets ................................................61
Appendix C – RS-422 Serial Interface .....................................................................................62
Appendix D - The RCI RS-422 Interface Specification .........................................................64
AppendixE – CONTROL-1500ACommunications Protocol .....................................................................71
APPENDIX G Drive Transfer Function ....................................................................................83
APPENDIX H Electrical Diagrams..........................................................................................84
Drive Board Layout...............................................................................................................84
Processor Board Layout .......................................................................................................85
Comm Port Wiring Legend ...................................................................................................86
RC1KADP Conversion..........................................................................................................87
RC1KADP Schematic...........................................................................................................88
RC2KPOL Schematic ..........................................................................................................89
RC2KHPP Schematic...........................................................................................................90
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]

Processor Board Schematic .................................................................................................91
Drive Board Schematic .........................................................................................................92
Declaration of Conformity.........................................................................................................93
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]

CONTROL-1500A Single Axis Antenna Controller Chapter 1
Chapter 1 INTRODUCTION
TheCONTROL-1500Aantennacontroller controls a single axis satellite antenna.TheCONTROL-1500A
interfaces to 36 volt actuators with single phase, pulse type position sense feedback. Two basicmodels
are available, the CONTROL-1500A and CONTROL-1500B. The CONTROL-1500B can track inclined
orbit satelliteswith either a single axistracking mount or a singleaxisfeed translation system.
The CONTROL-1500B isdescribed in an addendum to thismanual.
Here is a summary of the capabilities of the CONTROL-1500A…
1. The controller utilizes a solid state drive system capable of providing 8 amps to the antenna
actuator. The drive system has built-in over-current sensing with mechanical relay backup
to disconnect the drive from the actuator in the event of a fault.
2. The controller can control polarization via a polarotor (or servo) type interface. The
AUTO_POL feature allows the polarization to be controlled via a digital input or contact
closure supplied by a receiver to the controller. An RC2KPOL option is available to provide
control for a Seavey type two or four port feed with potentiometer feedback. If no
polarization control device will be present in a given installation configure the controller for
the servo option by setting the 24 vdc Rot Feed CONFIG mode item to ‘0’.
3. Position sensing feedback is supplied by a single phase, pulse based sensor - reed switch,
Hall effect, or electro-optical. Single phase reed switch and Hall effect type sensors are
found in 36 volt DC linear actuators. The CONTROL-1500keeps track ofboth rising and falling
pulse edges from the pulse sensor for increased accuracy. The pulse sensors used with
the CONTROL-1500 should not be coupled directlyto the antenna axisof rotation.
4. The CONTROL-1500’s non-volatile memorycan ‘remember’the positions ofa number of
geostationary satellites.
5. The Adapti-Drive variable speed control system allows the user to specify the desired slow
speed for the fundamental axis. The Adapti-Drive system will then adjust the actuator
voltage (via a pulse width modulation scheme) to maintain the speed selected by the user.
This alleviates the problem of poor speed regulation with varying direction along a given
axis associated with constant voltage slow speed systems.
6. The CONTROL-1500 isequipped with an RS-422 communications port. Thisallowsthe controller
to interface with a PC. The communication protocol used iscompatible with the popular
SA-Bus protocol. An optional RS-232 to RS-422 interface converter, designated
RC1KADP, isavailableto convert the RS-232 interface (which isstandard on PC's) over to
the RS-422 interface required for the SA-Bus protocol used on the CONTROL-1500.
1.1 Organization of this Manual
This manual is divided into two broad parts, Installation and Reference. The Installation part of
this manual is designed to familiarize the user with the controller and guide him or her through
the installation and configuration of the controller. The Reference portion of the manual gives
a detailed description of all of the features and capabilities of the controller.
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]

CONTROL-1500A Single Axis Antenna Controller Chapter 1Introduction 2
The Installation portion of the manual is comprised of Chapters 2 and 3. Chapter 2 explains
the user interface and the basic operation of the unit. Chapter 3 guides the user through the
physical installation and wiring of the unit as well as the initial software configuration.
The Reference portion of this manual is comprised of chapters 4, 5, and 6 as well as the
appendices which follow. These chapters of the manual describe the fields on the screens
which the user will encounter, as well as the data which can be entered at any prompt. After
the initial installation, when the user has become familiar with the operation of the controller,
these chapters will probably be the only ones consulted by the user to handle the routine
chores of adding new satellites and deleting old ones.
1.2 Before You Begin
Please read and understand the manual. Time invested in understanding the installation and
operation of the controller will insure satisfactory results. The unit has been tested thoroughly
and will work accurately and reliably if it is installed and configured properly. There is an old
saying in the controller business - "Garbage in, garbage out".
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]

CONTROL-1500A Single Axis Antenna Controller Chapter 2Basic Function Description3
Chapter 2 BASIC FUNCTION DESCRIPTION
This chapter describes the controller's front panel layout, user interface and basic operation.
When the user has completed this chapter, he or she should have an understanding of the
various operating modes of the unit, and be able to use the keyboard and liquid crystal display
(LCD) to navigate through those modes.
2.1 Front Panel
Thefront panel (figure 2.1) ofthe CONTROL-1500 contains an ON/OFF switch, a 2 row by 16 column
backlit LCD, and a 4 by 4matrixkeypad with tactilefeedback. The controller’s back panel is
described in chapter 3.
Figure 2.1 CONTROL-1500AFront Panel
The legend above the top row of the LCD defines the POS, POL, and SS fields. The POS field
is the current antenna position. POL defines the polarization field. SS is the signal strength
field. The three character field in the lower right hand corner of the LCD (above the MODE
label) is reserved for the display of the current controller mode. The various modes are
introduced in the following section. If an error condition is active, an error message will
periodically flash across the bottom row of the display. Error messages are discussed in
chapter 6. Chapter 4 explains the contents of every field on the display for all of the various
controller modes.
DAWNco • 3340 S. Lapeer Rd • Orion, MI 48359-1320 • Ph [phone] • Fax [phone] • [email protected]