RESEARCH CONCEPTS RC4600 User manual

RC4600 SERVO ANTENNA CONTROLLER BOARD SET
OPERATOR MANUAL
RESEARCU CONCEPTS INC.
9501 Dice Lane
Lenexa, Kansas 66215 USA
VOICE: [phone] FAX: [phone]
www.researchconcepts.com [e-mail]
Contents subject to change
Serial No___________

RC4600 ACU Board Set
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Revision History
DATE
MODIFICATION
SW VERSION
INITIALS
5 MAY 2017
Preliminary document, derived from RC4000 User’s
Manual
1.00
JDK
29 NOV 2017
Engineering Release
2.03
CJ
8 FEB 2019
Initial Production Release
2.10
RLE

RC4600 ACU Board Set
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Limited Warranty
New Products
Research Concepts, Inc., RCI, warrants to the original purchaser this product shall be free from defects in
material and workmanship for one year, unless expressed otherwise, from the date of the original
purchase. During the warranty period, RCI will provide, free of charge, both parts and labor necessary to
correct such defects.
To obtain such a warranty service, the original purchaser must:
1. Notify RCI as soon as possible after discovery of a possible defect, with:
a. Model and serial number
b. Purchase date
c. Detailed description of the problem and circumstances when problem appears, including
details on the electrical connection to associated equipment
2. Obtain an RMA number from RCI, then ship the product to RCI in original packaging or its
equivalent, fully insured and shipping/customs charges prepaid. RCI is not responsible for
damage during shipping.
Repaired Products
RCI warrants repairs to be free from defects in material and workmanship for six months from the repair
date. If a possible defect is found, use the same process as above to obtain service.
Repair fees for end users are a flat charge based on the equipment being repaired.
Repair fees for Dealers and OEMs are an hourly labor charge plus parts cost. ** Dealers and OEMs are
responsible for receiving and shipping the products from their customer. **
___
RCI will pay for domestic shipping to return the product using the same method that RCI received it.
Customers are responsible for all international shipping charges.
Correct maintenance, repair, and use are important to obtain proper performance from this product.
Therefore, read the instruction manual carefully and completely. This warranty does not apply to any
defect that RCI determines is due to, but not limited to:
1. Improper maintenance or repair, including the installation of parts or accessories that do not
conform to the quality and specifications of the original parts
2. Misuse, abuse, neglect, or improper installation including disregard for installation of backup or
safety override equipment
3. Accidental or intentional damage, including lightning
4. Water / Liquid damage
There are no implied warranties.
The foregoing constitutes RCI’s entire obligation with respect to this product, and the original purchaser
and any user or owner shall have no other remedy and no claim for incidental or consequential damages.
For service: [phone] support @researchconcepts.com

RC4600 ACU Board Set
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Table of Contents
1INTRODUCTION ...................................................................................................................................8
1.1 Manual Organization ......................................................................................................................8
1.2 Manual Conventions.......................................................................................................................9
1.3 RC4600 Features .........................................................................................................................10
1.4 Hardware Overview......................................................................................................................11
1.5 Software Overview........................................................................................................................12
1.5.1 Front Panel Overview............................................................................................................12
1.5.1.1 Operational Group Functions......................................................................................12
1.5.1.1.1 Manual........................................................................................................................12
1.5.1.1.2 Automatic Locate........................................................................................................12
1.5.1.1.3 Automatic Antenna Stow............................................................................................13
1.5.1.2 Programming Group Functions...................................................................................13
1.5.1.2.1Configuration Screens................................................................................................13
1.5.1.2.2 Maintenance Screens.................................................................................................13
1.5.2 Graphical User Interface Overview .......................................................................................14
1.6 Specifications................................................................................................................................15
2SOFTWARE.........................................................................................................................................16
2.1 Operation Overview......................................................................................................................16
2.1.1Front Panel Software Operation............................................................................................17
2.1.1.1 Front Panel Software Overview ..................................................................................17
2.1.1.1.1 Modes.........................................................................................................................17
2.1.1.1.2 Keypad Usage............................................................................................................18
2.1.1.1.3 Data Entry...................................................................................................................21
2.1.1.1.4 Display Layout............................................................................................................22
2.1.1.2 Front Panel Operating Group......................................................................................23
2.1.1.2.1 MANUAL Mode...........................................................................................................23

RC4600 ACU Board Set
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2.1.1.2.1.1 Heading Fix..........................................................................................................25
2.1.1.2.2 MENU Mode ...............................................................................................................27
2.1.1.2.2.1 DEPLOY...............................................................................................................27
2.1.1.2.2.2 STOW ..................................................................................................................28
2.1.1.2.2.3 LOCATE...............................................................................................................29
2.1.1.2.2.3.1 Satellite Selection..........................................................................................31
2.1.1.2.2.3.2 LOCATE Automatic Movement.....................................................................35
2.1.1.2.2.3.3 Azimuth Scan ................................................................................................36
2.1.1.2.2.3.4 Peak Up.........................................................................................................37
2.1.1.2.2.3.5 Box Peak.......................................................................................................38
2.1.1.2.2.3.6 Spiral Search.................................................................................................39
2.1.1.2.2.4 TRACK.................................................................................................................40
2.1.1.2.2.5 POSITION............................................................................................................42
2.1.1.2.2.5.1 LAT/LON........................................................................................................42
2.1.1.2.2.5.2 HEADING......................................................................................................43
2.1.1.2.2.5.3 TILT ...............................................................................................................44
2.1.1.2.2.6 MOVETO..............................................................................................................45
2.1.1.2.2.7 STANDBY............................................................................................................45
2.1.1.2.2.8 PEAKUP...............................................................................................................46
2.1.2 Graphical User Interface Software Overview........................................................................47
2.1.2.1 Graphical User Interface Main Page...........................................................................47
2.1.2.1.1 ACU Status Window...................................................................................................48
2.1.2.1.2 Antenna Position Display............................................................................................48
2.1.2.1.2.1 Alternate Position Displays..................................................................................49
2.1.2.1.2.1.1 Azimuth..........................................................................................................49
2.1.2.1.2.1.2 Elevation........................................................................................................50
2.1.2.1.3 Local Jog Control........................................................................................................51

RC4600 ACU Board Set
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2.1.2.1.4 Main Display Window.................................................................................................52
2.1.2.1.4.1 Satellite Arc Display.............................................................................................52
2.1.2.1.4.2 Spectrum Analyzer Display..................................................................................53
2.1.2.1.4.2.1 Frequency Controls.......................................................................................54
2.1.2.1.4.2.2 Amplitude Controls........................................................................................54
2.1.2.1.4.2.3 Bandwidth Controls.......................................................................................54
2.1.2.1.4.2.4 Marker Controls.............................................................................................55
2.1.2.1.4.3 Tracking Diagnostic .............................................................................................55
2.1.2.1.5 Automatic Operations.................................................................................................56
2.1.2.1.5.1 Deploy..................................................................................................................56
2.1.2.1.5.2 Stow.....................................................................................................................56
2.1.2.1.5.3 Locate ..................................................................................................................57
2.1.2.1.5.4 Track....................................................................................................................58
2.1.2.1.5.4.1 Start Track.....................................................................................................58
2.1.2.1.5.4.2 Resume Track...............................................................................................59
2.1.2.1.5.5 Peak Up ...............................................................................................................59
2.1.2.1.5.6 Move To...............................................................................................................60
2.1.2.1.5.7 Position ................................................................................................................61
2.1.2.1.5.7.1 Lat/Lon ..........................................................................................................61
2.1.2.1.5.7.2 Heading.........................................................................................................61
2.1.2.1.5.7.3 Tilt..................................................................................................................62
2.1.2.1.5.8 Toggle Standby....................................................................................................62
2.1.2.1.5.9 Drive Reset ..........................................................................................................62
2.1.2.1.6 Signal Strength and Transmit Status..........................................................................63
2.1.2.1.7 Maintenance...............................................................................................................64
2.1.2.2 Configuration Page .....................................................................................................65
2.1.2.2.1 Satellite Database ......................................................................................................66

RC4600 ACU Board Set
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2.1.2.2.1.1 Satellite Configuration..........................................................................................67
2.1.2.2.2System Settings..........................................................................................................68
2.1.2.2.2.1 ACU Configuration...............................................................................................68
2.1.2.2.2.2 GUI Configuration ................................................................................................68
2.1.2.2.2.3 Additional IP Devices...........................................................................................69
2.1.2.2.3 Advanced....................................................................................................................70
2.1.2.2.3.1 Satellite Database................................................................................................70
2.1.2.2.3.2 Configuration Data...............................................................................................71
2.1.2.2.3.3 TLE Data..............................................................................................................72
2.1.2.2.3.4 ACU Firmware......................................................................................................73
2.1.2.2.3.5 User Interface Firmware ......................................................................................74
3SUPPORT............................................................................................................................................75
3.1 Troubleshooting............................................................................................................................75
3.1.1 Warning Displays...................................................................................................................75
3.1.1.1 General Warnings .......................................................................................................75
3.1.1.2 Azimuth........................................................................................................................75
3.1.1.3 Elevation......................................................................................................................75
3.1.1.4 Polarization..................................................................................................................76
3.1.1.5 GPS.............................................................................................................................76
3.1.1.6 Compass .....................................................................................................................76
3.1.1.7 Dual Axis Inclinometer.................................................................................................76
3.1.2 Alarm Displays.......................................................................................................................77
3.1.2.1 General Alarms ...........................................................................................................77
3.1.2.2 Azimuth........................................................................................................................77
3.1.2.3 Elevation......................................................................................................................77
3.1.2.4 Polarization..................................................................................................................78
3.2 ACU Topics...................................................................................................................................79

RC4600 ACU Board Set
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3.2.1 Antenna Pointing Solution.....................................................................................................79
3.2.2 Polarization Control...............................................................................................................81
3.2.3 Drive System.........................................................................................................................81
3.2.4 Position Sensing and Limits..................................................................................................81
3.2.4.1 Follow, Drift, and Drive Error Sensing.........................................................................83
3.2.5 Timekeeping..........................................................................................................................83
3.2.6 Magnetic Variation.................................................................................................................84
3.2.7 System Performance.............................................................................................................85

RC4600 ACU Board Set Chapter 1 Introduction
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1 INTRODUCTION
The RC4600 Servo Antenna Control Unit (ACU) board set consists of a stackable set of cards allowing for
compact and flexible ACU packaging. The design and function of the RC4600 ACU is a continuation of
development based on the RC4000 line of mobile antenna control systems.
PLEASE READ AND UNDERSTAND THE MANUAL. Due to the complexity of the functions performed
by the RC4600, time invested in understanding its installation and operation will be well spent.
1.1 Manual Organization
The RC4600 board set allows for ACU functionality to be packaged in varied configurations. Also many
hardware and software options are available for use with the RC4600 architecture. This manual is
organized to:
1) Describe common hardware and software elements that will apply to all instances of the RC4600
2) Provide a structure to allow definition of elements unique to a specific use of the RC4600
Chapter 1 summarizes the contents of the manual and highlights the functionality and features of the
RC4600.
Chapter 2 describes the core software features of the RC4600.

RC4600 ACU Board Set Chapter 1 Introduction
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1.2 Manual Conventions
Throughout the manual, representations of screens the user will see will be shown in the boxed format
that follows:
A
Z
:
0
.
0
0
0
S
T
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W
B
C
N
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2
4
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1
4
:
2
5
:
4
7
The following table shows typical abbreviations used both on RC4600 screens and in the manual’s text.
ITEM
ABREVIATION(S)
Platform angles relative to reference position
az, el
Horizontal angles relative to the local horizontal
plane
AZ, EL
True Heading (estimate)
th
True Heading (fixed)
TH
Clockwise
CW
Counter-Clockwise (Anti-Clockwise)
CCW
Down
DN
Latitude
LAT
Longitude
LON
Satellite
SAT
Global Positioning System
GPS
Liquid Crystal Display
LCD
Signal Strength
SS
Satellite longitudes are presented in degree/decimal degree (79.0 W) format since that is the standard
representation of satellite positions. Latitude and longitude of the mount are presented in degree/minute
(38°56 N) format.
When referring to an RC4600 mode of operation, that mode’s name will be capitalized – ex. LOCATE.
Throughout the RC4600 manual and software, the latitude, longitude and true heading of the mount are
collectively referred to as the mount’s “position”.
Movements of the mount (as seen from behind the antenna, looking at the arc of satellites) are
represented by graphing the azimuth and elevation axes as shown below.

RC4600 ACU Board Set Chapter 1 Introduction
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1.3 RC4600 Features
The RC4600 performs its functions via digital and analog electronic equipment interfaced to the antenna’s
motor drive and position sensor systems. This equipment is controlled through embedded software
algorithms run by the RC4600’s microcontroller.
The RC4600 ACU is designed to automate the operation of mobile (both vehicle mounted and
deployable) mounts. Features provided include:
- Automatic azimuth and elevation pointing solution calculation
- Optional GPS receiver for determination of antenna latitude and longitude
- Automatic tracking of inclined orbit satellites
- Automatic polarization control of rotating feeds
- Battery backed-up non-volatile memory for storing satellite locations and configuration data
- Automatic repositioning to stored satellites
- Small stackable boards for flexible ACU packaging
- Continuous monitoring of antenna drive status
- Support for multiple band satellite operations
- Multiple Heading Sensor (Compass) Options
- Fluxgate Compass
- Three Axis Compass
- Differential GPS Antenna Compass "GPS Compass"
- Multiple User Interface Options
- Optional Liquid Crystal Display (LCD) and keypad
- Ethernet (IP-based) remote control
- Webpage Graphical User Interface (GUI)

RC4600 ACU Board Set Chapter 1 Introduction
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1.4 Hardware Overview
The following figure is a block diagram showing the four major components of the RC4600 board set and
how they interface with a typical antenna system.
Individual interfaces will be described in detail in Chapter 2. NOTE: Appendix C “Enclosure Specific
Data” will describe how these interfaces are mechanized for a board set in an enclosure.

RC4600 ACU Board Set Chapter 1 Introduction
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1.5 Software Overview
The RC4600 allows easy antenna control via its mode-based operation. Multiple user interfaces (local
and remote control) options exist. Section 1.5.1 highlights the software functions by showing data that
would be presented if a user interface utilizes the 4x4 keypad and 4x40 LCD screen. Section 0 highlights
the software functions by showing data that would be presented when using the graphical user interface
option. The screen displayed to the user is based on the current controller mode. Controller modes are
divided into two major groups: operational and programming. The operational modes provide for the
normal operation of the antenna. The programming group provides for initial configuration of the
controller and will typically not be used on a day by day basis. The following example highlights the basic
modes of operation provided by the RC4600.
1.5.1 Front Panel Overview
When using the physical font panel, or the remote front panel the screen displayed to the user is based
on the current controller mode. Controller modes are divided into two major groups: operational and
programming. The operational modes provide for the normal operation of the antenna. The
programming group provides for initial configuration of the controller and will typically not be used on a
day by day basis.
1.5.1.1 Operational Group Functions
1.5.1.1.1 Manual
In MANUAL mode the user may jog the antenna in Azimuth, Elevation and Polarization
A
Z
:
0
.
0
0
0
S
T
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W
B
C
N
:
2
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1.5.1.1.2 Automatic Locate
In LOCATE mode, azimuth and elevation pointing angles are automatically calculated based on position
data (Lat/Lon), platform heading, platform pitch/roll and the selected satellite. Position data may be
obtained automatically from a GPS receiver, selected from a preset list of user defined positions or
entered manually. Heading may be automatically obtained from a compass or entered manually. The
platform pitch/roll will be automatically obtained from a tilt sensor. The user selects which satellite to
locate from the satellite database or by manually entering satellite data. The RC4600 checks that the
calculated pointing solution is within the antenna’s range of movement and prompts the user to
automatically position the antenna.
A
N
T
:
3
8
_
5
7
N
9
4
_
4
5
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1
7
8
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A
T
E

RC4600 ACU Board Set Chapter 1 Introduction
13
1.5.1.1.3 Automatic Antenna Stow
From STOW mode, the user may ask for the antenna to be automatically moved to the stow position.
a
z
:
0
.
0
0
0
(
0
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)
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1.5.1.2 Programming Group Functions
1.5.1.2.1 Configuration Screens
Configuration mode screens allow the user to customize and calibrate the operation of the RC4600 for
use with a particular antenna. Note that most configuration items will be factory set for correct operation
with a particular antenna.
M
O
D
E
:
2
A
N
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4
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5
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P
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>
1.5.1.2.2 Maintenance Screens
Maintenance mode screens allow the user to monitor sensor inputs and perform periodic maintenance
actions such as setting time and resetting drive errors.
S
Y
S
T
E
M
:
1
0
/
2
2
/
1
8
1
6
:
5
7
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5
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F
F
S
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T

RC4600 ACU Board Set Chapter 1 Introduction
14
1.5.2 Graphical User Interface Overview
The graphical user interface control option is available via the IP interface of the controller. It is designed
to provide all the functions available from the front panel operation in an easy to use interface. As well as
provide current information of the system.

RC4600 ACU Board Set Chapter 1 Introduction
15
1.6 Specifications
RC4600 BOARDSET
Physical
Size
6 1/16" x 7" x 3 3/4" (with RCI plate and RF board)
Weight
2.6 lbs.
Input Power
Default: 20 - 28 VDC
Other options available
Fusing
Mount and input power dependent
Temperature (Operational)
-40 to +60 deg. C.
Temperature (Storage)
-40 to +70 deg C.
Humidity
35% to 85% (optional special-environmental kit available)
Antenna Drive
Azimuth/Elevation
Default: 24VDC, 20 Amps (combined AZ/EL)
Other options available
Polarization
24VDC, 2 Amps
Electromechanical Brakes
(optional)
24 VDC, 850 mA
Position Sense
Azimuth/Elevation
ENDAT optical encoder (25 bit) or Resolver (16 bit)
Polarization
ENDAT optical encoder (23 bit), Resolver (16 bit), Multi-Turn Potentiometer
Limit Switch Inputs
5 VDC inputs, standard: EL Up, EL Down, EL Stow, AZ Stow, Pol Stow
typical + additional inputs optional, mount dependent
Locate Mode
AZ/EL Pointing Accuracy
±0.006° (Resolver), ±0.001° (Optical Encoder)
POL Pointing Accuracy
±0.08° (typical)
Pitch and Roll Sensing
±15° pitch and roll
VSAT Mode
Single key-press-to-locate-operation for untrained operators
Positive Satellite
Identification
Multiple Beacon Tracking Receiver Options, DVB-S2, and Spectrum
Analyzer.
External AGC
Support for external analog signal source and lock input
Track Mode
Antenna Size
0.4 – 10.0 meters
Tracking Accuracy
0.1 to 3.0 dB selectable; mount dependent
Maximum Inclination
15°, standard
Inclined Orbit Tracking
Modes
Step-Tracking, Step/Memory Tracking, Predictive Tracking, NORAD TLE
tracking

RC4600 ACU Board Set Chapter 1 Introduction
16
2 SOFTWARE
2.1 Operation Overview
The RC4600 allows multiple options for mechanizing the user interface. These can be divided into 2
distinct groups.
The first are versions that utilize a 4x4 keypad and 4x40 LCD display. Operation using this method will
be described in section 0 and includes the following methods of control:
•Rackmount 4600 Front Panel
•Handheld Remote Front Panel
•IP based remote front panel
The second is an IP based graphical user interface (GUI) method of control. Operation using this method
will be described in section 0.

RC4600 ACU Board Set Chapter 1 Introduction
17
2.1.1 Front Panel Software Operation
2.1.1.1 Front Panel Software Overview
2.1.1.1.1 Modes
The functionality of the RC4600 is achieved by placing the controller in the desired mode of operation.
The diagram below shows the hierarchy of the RC4600’s modes. Each mode has a unique display
screen that presents the information applicable to that mode’s operation.
Transition between groups by holding down the MODE key for 5 seconds
OPERATING GROUP PROGRAMMING GROUP
Transition between modes by pressing the
MODE key
Transition between modes by pressing the
MODE key
MANUAL
MENU
2.1.1.2.1
2.1.1.2.2
DEPLOY
2.1.1.2.2.1
STOW
2.1.1.2.2.2
LOCATE
2.1.1.2.2.3
TRACK
2.1.1.2.2.4
POSITION
2.1.1.2.2.5
MOVETO
2.1.1.2.2.6
STANDBY
2.1.1.2.2.7
PEAKUP
2.1.1.2.2.8
After initial pairing of an RC4600 to an antenna, the programming modes will typically not be used.
Section 2.1.1.2 will give further details on the operating modes. The rest of section 2.1.1 introduces
common elements of all modes.

RC4600 ACU Board Set Chapter 1 Introduction
18
2.1.1.1.2 Keypad Usage
The keypad provides a flexible method of controlling the functionality of the RC4600. While each RC4600
mode has different requirements for user input, the use of the keypad remains consistent throughout all
modes.
The keypad provides for both specific actions and general data input. As an example, the <2/UP/N> key
initiates an antenna up movement while in MANUAL mode but also allows for the entry of the number 2
when numeric entry is required or the indication of North when entering a latitude value. The required key
usage is provided in the detailed description of each mode.
The table on the following page describes both the specific action and general data entry function of each
key.