RESEARCH CONCEPTS RC4000 User manual

RC4000 ANTENNA CONTROLLER BOARDSET
USER’S MANUAL
RESEARCH CONCEPTS INC.
9501 Dice Lane
Lenexa, Kansas 66215 USA
VOICE: [phone] FAX: [phone]
www.researchconcepts.com [e-mail]
Contents subject to change
Serial No________

RC4000 ACU Boardset Chapter 1 Introduction
REVISION HISTORY
DATE
MODIFICATION
SW VERSION
INITIALS
07 JAN 2011
Preliminary document
0.00
CJ
15 FEB 2011
Engineering release
0.02
CJ
10 MAR 2011
Initial release
0.03
CJ
26 MAR 2012
System Definition screen
0.05
JFR
12 JUN 2012
Expert Access/Reset Defaults updates
0.05
ECG
10 AUG 2012
Polarization Calibration Multi-Feeds
0.05
JFR
28 NOV 2012
Updated section of fix heading
0.05
ECG
25 NOV 2013
Corrected feed bit significance
0.06
ECG
26 NOV 2013
Corrected Bus A & B tables, change
chapter 5 to Appendix A, add Appendix B
& C nomenclature
0.06
JDK
05 DEC 2013
Large update to many parts of the
manual, references, drawings,
descriptions, troubleshooting, etc.
0.06
JDK
26 AUG 2014
Updated appendix list
0.07
BPK
11 NOV 2014
Updated many CONFIG screens &
definitions
1.10
JDK
03 DEC 2014
Updated pulse scale factor desc AZ/EL
1.1x
JDK
10 MAR 2015
Updated max inclination spec
1.1x
JFR
18 JUN 2015
Corrected discrepancies in the AZ Jam
Slop and Runaway Slop descriptions
1.1x
JDK
10 JUL 2015
Updated Options Board to new design
1.1x
JDK
10 JUL 2015
Updated Magnetic Variation map
1.1x
ECG
23 SEP 2015
Updated Sensors in Specifications
1.1x
JDK
27 SEP 2016
Large update of CONFIG mode with
transition to software version 2.0x.
Updated CONFIG screens, parameters, etc.
Corrected some old references to RC3000
in the trouble-shooting section.
Created hyper-links for chapter &
section references within the document.
2.03
JDK
10 NOV 2016
Updated warranty
N/A
BPK

RC4000 ACU Boardset Chapter 1 Introduction
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

RC4000 ACU Boardset Chapter 1 Introduction
TABLE OF CONTENTS
1.0 INTRODUCTION.................................................................................................................................................1
1.1 MANUAL ORGANIZATION.....................................................................................................................................1
1.2 RC4000 FEATURES ..............................................................................................................................................3
1.3 HARDWARE OVERVIEW........................................................................................................................................4
1.4 SOFTWARE OVERVIEW .........................................................................................................................................5
1.5 SPECIFICATIONS ...................................................................................................................................................7
1.6 PART NUMBER SCHEME .......................................................................................................................................8
2.0 HARDWARE.........................................................................................................................................................9
2.1 BOARDSET DEVICES.............................................................................................................................................9
2.1.1 Mechanical Mounting...................................................................................................................................9
2.1.2 Electrical Interfaces ...................................................................................................................................13
2.1.2.1 Power/Drive Board ................................................................................................................................................14
2.1.2.1.1 J1 - AC Power Input....................................................................................................................................... 15
2.1.2.1.2 J2 - DC power................................................................................................................................................. 16
2.1.2.1.3 J3 - Interboard Bus B...................................................................................................................................... 16
2.1.2.1.4 J4 - JTAG ....................................................................................................................................................... 16
2.1.2.1.5 J5 - Motor Drive............................................................................................................................................. 17
2.1.2.1.6 J6 - DC Power Input.......................................................................................................................................18
2.1.2.2 Computing and Interface Board.............................................................................................................................19
2.1.2.2.1 J1 - Interboard Bus B.....................................................................................................................................20
2.1.2.2.2 J2 - Red / Green Buttons................................................................................................................................21
2.1.2.2.2 J2 - Red / Green Buttons................................................................................................................................21
2.1.2.2.3 J3 - Receiver 1...............................................................................................................................................22
2.1.2.2.4 J4 - Serial Remote Control.............................................................................................................................23
2.1.2.2.5 J5 - Interboard 24 VDC ................................................................................................................................. 24
2.1.2.2.6 J6 - Software Download ................................................................................................................................ 24
2.1.2.2.7 J7 - Interboard Bus A.....................................................................................................................................25
2.1.2.2.8 J8 - Temperature Sensor................................................................................................................................ 26
2.1.2.2.9 J9 - LCD........................................................................................................................................................26
2.1.2.2.10 J10 - Keypad.................................................................................................................................................27
2.1.2.2.11 J11 - Processor JTAG...................................................................................................................................27
2.1.2.2.12 J12 - PLD JTAG...........................................................................................................................................27
2.1.2.2.13 J13A - Polarization Sensors..........................................................................................................................28
2.1.2.2.14 J13B – ACC/Compass..................................................................................................................................29
2.1.2.2.15 J14A - Azimuth Sensors...............................................................................................................................30
2.1.2.2.16 J14B - Elevation Sensors.............................................................................................................................. 31
2.1.2.3 Resolver Card ........................................................................................................................................................32
2.1.2.3.1 J1 - Interboard 24 VDC ................................................................................................................................. 33
2.1.2.3.2 J2 – Interboard Bus A....................................................................................................................................33
2.1.2.3.3 J3 – Extra IO.................................................................................................................................................. 33
2.1.2.3.4 J4 – Pol Resolver........................................................................................................................................... 34
2.1.2.3.5 J5 – El Resolver............................................................................................................................................. 35
2.1.2.3.6 J6 – Az Resolver............................................................................................................................................35
2.1.2.4 Options Board........................................................................................................................................................36
2.1.2.4.1 J1 - Interboard 24 VDC ................................................................................................................................. 37
2.1.2.4.2 J2 – Receiver 2 ..............................................................................................................................................37
2.1.2.4.3 J3 - Compass/Inclinometer ............................................................................................................................38
2.1.2.4.4 J4 - Relay....................................................................................................................................................... 39
2.1.2.4.5 J5 - Bar LEDs................................................................................................................................................ 39
2.1.2.4.6 J6 - Interboard Bus A.....................................................................................................................................40
2.1.2.4.7 J7 -LEDs......................................................................................................................................................40
2.1.2.4.8 J8 - RF Input..................................................................................................................................................41
2.1.2.4.9 J9 - Ethernet...................................................................................................................................................42
2.1.2.4.10 J10 - Audio................................................................................................................................................... 42
2.1.2.4.11 J11 - JTAG ...................................................................................................................................................42
2.1.2.4.12 J12 - Fan1..................................................................................................................................................... 42
2.1.2.4.13 J13 - Fan2..................................................................................................................................................... 42
2.1.2.4.14 J14 - IP Reset................................................................................................................................................43

RC4000 ACU Boardset Chapter 1 Introduction
2.1.2.4.15 Heater.......................................................................................................................................................... 43
2.1.2.4.16 J15 - GPS ..................................................................................................................................................... 44
2.1.2.4.16 J22 – GPS PPS............................................................................................................................................. 45
2.1.2.4.17 J21 – DVB-S2.............................................................................................................................................. 46
2.1.2.4.18 J23 – Auxiliary 3.3V Out............................................................................................................................. 46
2.1.2.5 Connectors............................................................................................................................................................. 47
2.1.2.5.1 Phoenix Terminal Header............................................................................................................................... 47
2.1.2.5.2 Molex Friction Lock....................................................................................................................................... 47
2.1.2.5.3 Right Angle Shrouded Header ....................................................................................................................... 47
2.1.2.5.4 JTAG Programming....................................................................................................................................... 47
2.1.2.5.5 Drive Terminal Block..................................................................................................................................... 47
2.1.2.5.6 Phoenix Header.............................................................................................................................................. 47
2.1.2.5.7 USB................................................................................................................................................................ 48
2.1.2.5.8 Tyco Vertical Header..................................................................................................................................... 48
2.1.2.5.9 Unshrouded Header........................................................................................................................................ 48
2.1.2.5.10 Phoenix Double Header................................................................................................................................ 48
2.1.2.5.11 SMB COAX................................................................................................................................................. 48
2.1.2.5.12 Ethernet........................................................................................................................................................ 48
2.1.2.5.13 Phoenix Header............................................................................................................................................ 48
2.2 EXTERNAL EQUIPMENT...................................................................................................................................... 49
2.2.1 Electronic Clinometer................................................................................................................................ 49
2.2.2 External GPS Receiver............................................................................................................................... 51
2.2.3 Fluxgate Compass...................................................................................................................................... 52
2.2.4 Single Axis Compass.................................................................................................................................. 53
2.2.5 LCD............................................................................................................................................................ 53
2.2.6 4x4 Keypad................................................................................................................................................. 53
2.2.7 Local Jog Control Panel............................................................................................................................ 54
2.2.8 Handheld Remote Front Panel................................................................................................................... 55
3.0 SOFTWARE........................................................................................................................................................ 57
3.1 OPERATION OVERVIEW...................................................................................................................................... 57
3.1.1 Modes......................................................................................................................................................... 57
3.1.2 Keypad Usage............................................................................................................................................ 58
3.1.3 Data Entry.................................................................................................................................................. 61
3.1.4 Display Layout........................................................................................................................................... 62
3.1.5 Software Initialization................................................................................................................................ 63
3.2 OPERATING GROUP............................................................................................................................................ 67
3.2.1 Manual Mode............................................................................................................................................. 67
3.2.1.1 Heading Fix........................................................................................................................................................... 69
3.2.2 Menu Mode ................................................................................................................................................ 70
3.2.2.1 Deploy................................................................................................................................................................... 71
3.2.2.2 Stow....................................................................................................................................................................... 72
3.2.2.3 Locate.................................................................................................................................................................... 73
3.2.2.3.1 Satellite Selection........................................................................................................................................... 74
3.2.2.3.2 LOCATE Automatic Movement.................................................................................................................... 76
3.2.2.3.3 Azimuth Scanning Autopeak.......................................................................................................................... 77
3.2.2.3.4 Spiral Search Autopeak.................................................................................................................................. 79
3.2.2.3.5 Terminal Peak Up .......................................................................................................................................... 80
3.2.2.3.6 Polarization Tilt Compensation...................................................................................................................... 80
3.2.2.4 Store ...................................................................................................................................................................... 81
3.2.2.5 Recall..................................................................................................................................................................... 82
3.2.2.6 Delete .................................................................................................................................................................... 82
3.2.2.7 Position.................................................................................................................................................................. 83
3.2.2.7.1 LAT/LON....................................................................................................................................................... 83
3.2.2.7.2 HEADING ..................................................................................................................................................... 84
3.2.2.8 Settings.................................................................................................................................................................. 85
3.2.2.9 Track...................................................................................................................................................................... 86
3.2.2.10 VSAT Mode........................................................................................................................................................ 87
3.3 PROGRAMMING GROUP...................................................................................................................................... 92
3.3.1 Configuration Mode................................................................................................................................... 92
3.3.1.1 NORMAL ACCESS ITEMS................................................................................................................................. 94
3.3.1.1.1 Expert Access Level....................................................................................................................................... 94
3.3.1.1.2 Preset Locations............................................................................................................................................. 95
3.3.1.1.3 Preset Satellites .............................................................................................................................................. 96

RC4000 ACU Boardset Chapter 1 Introduction
3.3.1.2 INSTALLATION ACCESS ITEMS......................................................................................................................98
3.3.1.2.1 System Definition........................................................................................................................................... 98
3.3.1.2.2 Elevation Calibration....................................................................................................................................100
3.3.1.2.3 Azimuth Calibration.....................................................................................................................................101
3.3.1.2.4 Polarization Calibration................................................................................................................................102
3.3.1.2.5 Feed Definition.............................................................................................................................................105
3.3.1.2.6 Autopeak ......................................................................................................................................................107
3.3.1.2.7 SS1 Signal Strength Factors ........................................................................................................................109
3.3.1.2.8 SS2 Signal Strength Factors ........................................................................................................................110
3.3.1.2.9 RF Signal Strength Factors..........................................................................................................................111
3.3.1.3 Super-User Access Items .....................................................................................................................................112
3.3.1.3.1 Reset Defaults............................................................................................................................................... 112
3.3.1.3.2 Azimuth Angle Movement ...........................................................................................................................113
3.3.1.3.3 Azimuth Count Movement...........................................................................................................................114
3.3.1.3.4 Azimuth Drive Parameters............................................................................................................................ 115
3.3.1.3.5 Elevation Angle Movement.......................................................................................................................... 117
3.3.1.3.6 Elevation Count Movement..........................................................................................................................118
3.3.1.3.7 Elevation Drive Parameters.........................................................................................................................119
3.3.1.3.8 Polarization Angle Movement......................................................................................................................121
3.3.1.3.9 Pol Drive Parameters....................................................................................................................................123
3.3.1.3.10 Stow & Deploy Positions............................................................................................................................126
3.3.1.3.11 SHAKE....................................................................................................................................................... 129
3.3.2 Maintenance Items ...................................................................................................................................130
3.3.2.1 Analog to Digital Voltage....................................................................................................................................131
3.3.2.1.1 10 Bit ADC Voltages....................................................................................................................................131
3.3.2.1.2 12 Bit ADC Voltages....................................................................................................................................132
3.3.2.2 Drive Error Resets................................................................................................................................................133
3.3.2.3 Time Maintenance ............................................................................................................................................... 133
3.3.2.4 TBD Maintenance................................................................................................................................................ 134
3.3.2.5 Limits Maintenance .............................................................................................................................................135
3.3.2.6 GPS Serial Port Diagnostics................................................................................................................................. 136
3.3.2.7 Fluxgate Serial Port Diagnostics..........................................................................................................................136
3.3.2.8 MOVETO ............................................................................................................................................................ 137
3.3.2.9 Fluxgate Calibration Procedure............................................................................................................................138
3.3.2.10 Shake..................................................................................................................................................................139
3.3.2.11 System Information............................................................................................................................................ 140
4.0 SUPPORT..........................................................................................................................................................141
4.1 INSTALLATION..................................................................................................................................................141
4.1.1 Software Initialization..............................................................................................................................142
4.1.2 Elevation Calibration...............................................................................................................................144
4.1.3 Azimuth Calibration.................................................................................................................................148
4.1.4 Polarization Calibration ..........................................................................................................................151
4.1.5 Fast/Slow Motor Speed.............................................................................................................................154
4.1.6 Pulse Sensor Checkout.............................................................................................................................154
4.1.7 Drive System Checkout.............................................................................................................................154
4.1.8 Navigation Sensor Communication..........................................................................................................154
4.1.9 Compass Calibration................................................................................................................................155
4.1.10 Azimuth and Elevation Alignment ..........................................................................................................156
4.1.11 Signal Strength Adjustment ....................................................................................................................158
4.1.11.1 L-Band Power Detector .....................................................................................................................................158
4.1.11.2 Signal Strength Channel.....................................................................................................................................158
4.1.11.3 Signal Strength Channel Configuration .............................................................................................................158
4.1.11.4 Amplifier Gain vs. Frequency Characterization.................................................................................................159
4.1.12 Pulse Scale Factors................................................................................................................................160
4.1.13 Operational Presets................................................................................................................................162
4.1.14 Miscellaneous Adjustments ....................................................................................................................162
4.1.15 Mechanizing Automatic Locates.............................................................................................................162
4.2 TROUBLESHOOTING..........................................................................................................................................164
4.2.1 Limit Switches...........................................................................................................................................164
4.2.2 Motor Drive..............................................................................................................................................165
4.2.3 Automatic Movements ..............................................................................................................................166
4.2.4 GPS...........................................................................................................................................................166
4.2.5 Fluxgate Compass....................................................................................................................................167

RC4000 ACU Boardset Chapter 1 Introduction
4.2.6 Alarm Displays......................................................................................................................................... 168
4.2.6.1 FLASH / NVRAM VERSION MISMATCH...................................................................................................... 168
4.2.6.2 FLASH / NVRAM DATA CORRUPT ............................................................................................................... 168
4.2.6.3 LOW BATTERY ALARM ................................................................................................................................. 168
4.2.6.4 TIME / DATE ERROR ....................................................................................................................................... 168
4.2.6.5 AZIMUTH / ELEVATION / POLARIZATION JAMMED ............................................................................... 168
4.2.6.6 AZIMUTH / ELEVATION / POLARIZATION RUNAWAY ........................................................................... 168
4.2.6.7 LIMITS INACTIVE WARNING........................................................................................................................ 168
4.2.6.8 DRIVE OVERTEMP .......................................................................................................................................... 169
4.2.6.9 DRIVE ERROR................................................................................................................................................... 169
4.2.6.10 EMERGENCY STOP........................................................................................................................................ 169
4.2.6.11 REPLACE HAND CRANKS............................................................................................................................ 169
4.2.6.12 ELEVATION INTERLOCK............................................................................................................................. 169
4.2.6.13 MOVEMENT INTERLOCK............................................................................................................................. 169
4.2.6.14 LOCAL JOG CONTROLLER CONNECTED ................................................................................................. 169
4.3 ACU TOPICS.................................................................................................................................................... 170
4.3.1 Antenna Pointing Solution ....................................................................................................................... 170
4.3.2 Timekeeping............................................................................................................................................. 172
4.3.3 Drive System ............................................................................................................................................ 172
4.3.4 Polarization Control................................................................................................................................ 174
4.3.5 Magnetic Variation.................................................................................................................................. 175
4.3.6 System Performance................................................................................................................................. 176
APPENDIX A – EXPERT ACCESS CODES
APPENDIX B – MOUNT SPECIFIC DATA
APPENDIX C – ENCLOSURE SPECIFIC DATA
The following appendices describe optional features of the RC4000. These appendices will be
included in the manual if the option is present.
APPENDIX BCN : INTEGRATED BEACON RECEIVER
APPENDIX DVB : INTEGRATED DVB-S RECEIVER
APPENDIX DVB-S2 : INTEGRATED DVB-S2 RECEIVER
APPENDIX IP : IP-BASED REMOTE CONTROL
APPENDIX PBO : PUSH BUTTON OPERATION
APPENDIX SAC : SINGLE-AXIS COMPASS
APPENDIX REM : SERIAL-BASED REMOTE CONTROL
APPENDIX TAC : THREE-AXIS COMPASS
APPENDIX TLE : TWO LINE ELEMENT TRACKING
APPENDIX TRK : INCLINED ORBIT TRACKING

RC4000 ACU Boardset Chapter 1 Introduction
1
1.0 INTRODUCTION
The RC4000 Antenna Control Unit (ACU) boardset consists of stackable set of cards allowing for compact
and flexible ACU packaging. The design and function of the RC4000 is derived from Research Concepts
Incorporated's previous generation mobile ACU, the RC3000.
PLEASE READ AND UNDERSTAND THE MANUAL. Due to the complexity of the functions performed
by the RC4000, time invested in understanding its installation and operation will be well spent.
1.1 Manual Organization
The RC4000 boardset allows for ACU functionality to be packaged in varied configurations. Also many
hardware and software options are available for use with the RC4000 architecture. This manual is
organized to:
1) describe common hardware and software elements that will apply to all instances of the RC4000 and
2) provide a structure to allow definition of elements unique to a specific use of the RC4000
Chapter 1 summarizes the contents of the manual and highlights the functionality and features of the
RC4000.
Chapter 2 describes the RC4000 boardset hardware, interfaces and common external components.
Chapter 3 describes the core software features of the RC4000.
Chapter 4 covers RC4000 common installation and calibration procedures, provides help for system
troubleshooting and discusses detailed operational topics referred to in the manual
Appendix A supplies the expert access codes on a single page, which at management’s discretion, may
be removed to eliminate the possibility of inexperienced users inadvertently corrupting configuration data.
Appendix B, titled "MOUNT SPECIFIC DATA", details unique functions and values unique to a specific
antenna mount.
Appendix C, titled "ENCLOSURE SPECIFIC DATA", details mechanical and electrical details on how the
RC4000 is packaged. This appendix may not be supplied from RCI if the boardset is not packaged in an
RCI provided enclosure.
Separate appendices describe optional features of the RC4000. Example optional appendices that could
accompany the manual include:
APPENDIX REM - SERIAL-BASED REMOTE CONTROL
APPENDIX IP - IP-BASED REMOTE CONTROL
APPENDIX TRK - INCLINED ORBIT TRACKING
APPENDIX TLE - TWO LINE ELEMENT TRACKING
APPENDIX DVB - INTEGRATED DVB RECEIVER
APPENDIX BCN - INTEGRATED BEACON RECEIVER

RC4000 ACU Boardset Chapter 1 Introduction
2
MANUAL CONVENTIONS
Throughout the manual, representations of screens the user will see will be shown in the boxed format
that follows:
AZIM: 0.0 STOW SS1: 50 MANUAL
ELEV: -67.5 STOW SAT:TELSTAR 402
POL: 0.0 SPD:FAST CST
<0-9>JOG ANTENNA <MODE>MENU 14:25:47
The following table shows typical abbreviations used both on RC4000 screens and in the manual’s text.
ITEM
ABREVIATION(S)
Azimuth
AZ
AZIM, Azim
Elevation
EL
ELEV, Elev
Polarization
PL
POL, Pol
Clockwise
CW
Counter-Clockwise (Anti-Clockwise)
CCW
Down
DN
Latitude
LAT
Longitude
LON
Satellite
SAT
Global Positioning System
GPS
Liquid Crystal Display
LCD
Automatic Gain Control
AGC
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 a particular RC4000 mode of operation, that mode’s name will be capitalized – ex.
LOCATE.
Throughout the RC4000 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.

RC4000 ACU Boardset Chapter 1 Introduction
3
1.2 RC4000 Features
The RC4000 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 RC4000’s microcontroller.
The RC4000 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
- Optional 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
- Single Axis Compass
- Dual GPS Antenna Module "GPS Compass" (future)
- Multiple User Interface Options
- Optional Liquid Crystal Display (LCD) and keypad
- Serial (RS-422/-232) remote control
- Ethernet (IP-based) remote control
- Red/Green Button
The following picture shows an example of the RC4000 boardset mounted in a weatherproof enclosure.
This picture shows removable connectors on the enclosure but antenna interface wiring could go directly
to boardset connectors (via cable glands, etc.) if so desired.

RC4000 ACU Boardset Chapter 1 Introduction
4
1.3 Hardware Overview
The following figure is a block diagram showing the major components of the RC4000 boardset 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 particular enclosure.
J6
AC INPUT
DC INPUT

RC4000 ACU Boardset Chapter 1 Introduction
5
1.4 Software Overview
The RC4000 allows easy antenna control via its mode based operation.Multiple user interface (local and
remote control) options exist. This overview highlights the software functions by showing data that would
be presented if a user interface utilizes an LCD screen. 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
RC4000.
Operational Group Functions
MANUAL. In MANUAL mode the user may jog the antenna in azimuth, elevation and polarization. Upon
power up, the fluxgate compass and GPS receiver initialize and begin providing data.
AZIM: 0.0 STOW SIG: 50 MANUAL
ELEV: -67.5 STOW SAT:TELSTAR 402
POL: 0.0 SPD:FAST CST
<0-9>JOG ANTENNA <MODE>MENU 14:25:47
AUTOMATIC LOCATION OF A SATELLITE. In LOCATE mode, azimuth and elevation pointing angles
are automatically calculated based on position (lat/lon), heading and the selected satellite. Position may
be obtained automatically from the optional GPS, selected from a preset list of user defined positions or
entered manually. Heading may be automatically obtained from the optional fluxgate compass or entered
manually. The user selects which satellite to locate from either a preset user defined list of commonly
used satellites, a provided extensive list of satellites or by manually entering satellite data. The RC4000
checks that the calculated pointing solution is within the mount’s range of movement and prompts the
user to automatically position the antenna.
POS: 38°56N 94°44W 180.0 LOCATE
SAT:GALAXY 6 74.0W AZ:-31.1
EL: 40.0
<1>SELECT NEW SAT READY TO LOCATE
STORING SATELLITE LOCATION. After verifying the antenna is precisely on the satellite, the user may
STORE the satellite’s azimuth and elevation angles along with horizontal and vertical polarization data. If
the satellite has been identified as having an inclined orbit, the TRACK mode will be automatically
entered as described below.
SAT LON INCLIN BAND STORE
BRASIL A1 79.0 2 C
VERIFY SATELLITE DATA OK FOR STORING
1-CORRECT, 2-INCORRECT
RECALLING STORED SATELLITES. The user may quickly and precisely move between previously
STOREd satellites via RECALL mode.

RC4000 ACU Boardset Chapter 1 Introduction
6
RECALL
STORED SATELLITE: BRASIL A1
SELECT SAT(SCROLL UP/DOWN) <ENTER>
AUTOMATIC ANTENNA STOWING. From STOW mode, the user may ask for the antenna to be
automatically moved to the stow position.
AZIM: -42.5 ( 0.0) STOW
ELEV: 23.4 (-67.5)
MOVING TO (TARGET),<STOP> TO HALT MOTION
Programming Group Functions
The programming group modes provide for initial configuration of the controller and also provide screens
to aid in maintenance and troubleshooting.
Configuration mode screens allow the user to customize and calibrate the operation of the RC4000 for
use with a particular mount. Note that most configuration items will be factory set for correct operation
with a particular mount.
REF_VOLT:2.50 OFF: 0.0 CONFIG-AZIM
CCW:180 CW:180 SF:76.35
SET REFERENCE VOLTAGE <2.00 - 3.00>
Maintenance mode screens allow the user to monitor sensor inputs and perform periodic maintenance
actions such as setting time and resetting drive errors.
SYSTEM:11/10/97 22:26:40 TIME
GPS UTC:11/10/97 22:26:40 ZONE:CST
DISPLAY:11/10/97 16:26:40 OFFSET:- 6
1-DATE 2-TIME 3-SYNCH 4-ZONE 5-OFFSET

RC4000 ACU Boardset Chapter 1 Introduction
7
1.5 Specifications
RC4000 BOARDSET
Physical
Size
6 1/16" x 7" x 3 3/4" (with RCI plate and RF board)
Weight
2.6 lbs.
Input Power
AC: 85 - 265 VAC, 47 - 63 Hz
DC: 20 - 28 VDC
Fusing
3 AMP Slow-Blow
Temperature (Operational)
-40 to +60 deg. C.
Temperature (Storage)
-40 to +70 deg C.
Humidity
10% to 85% Non-Condensing (optional special-environmental kit available)
Antenna Drive
Azimuth/Elevation/Polarization
24 VDC
10 A. (300 W. power supply), 17 A. (500 W. power supply)
Electromechanical Brakes
(optional)
24 VDC, 850 mA
Position Sense
Azimuth
Potentiometer, 12-bit resolution standard; quadrature pulse sensor
standard, optional single phase pulse sensors (Reed, Hall-Effect, Optical);
optional resolver, 16-bit resolution
Elevation
Inclinometer, 12-bit resolution standard; quadrature pulse sensor standard,
optional single phase pulse sensors (Reed, Hall-Effect, Optical); optional
resolver, 16-bit resolution
Polarization
Potentiometer, 12-bit resolution standard; optional single phase pulse
sensor, optional resolver, 16-bit resolution
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
Elevation Accuracy
+/- 0.02 degrees (typical)
Azimuth Accuracy
+/- 0.10 degrees (typical)
Polarization Accuracy
+/- 0.08 degrees (typical)
VSAT Mode
Single key-press-to-locate-operation for untrained operators
Autopeak Input
Full L-Band power detection to find strongest signal.(configurable to AGC
voltage or Beacon receiver output -10 VDC to +10 VDC; 2Mohm input
impedance, two channels)
Modem Receive-Lock Input
TTL or contact closure, (optional non-invasive modem lock detector
available)
Track Mode
Antenna Size
0.4 – 12.0 meters
Tracking Accuracy
0.1 to 3.0 dB selectable; mount dependent
Maximum Inclination
12 deg., standard
Inclined Orbit Tracking Modes
Step-Track, Memory-Track, Intelli-Search™ , Program Track, optional
Ephemeris Track
Signal-Strength Input
-10 VDC to +10 VDC; 2Mohm input impedance, two channels
Non-volatile Memory Backup
Duracell DL2450

RC4000 ACU Boardset Chapter 1 Introduction
8
1.6 Part Number Scheme
As of January, 2011 the RC4000 part numbering scheme consisted of 20 digits. This scheme is
introduced here as a way to highlight many of the options (both hardware and software) associated with
customizing an ACU solution using the RC4000. The following table only briefly discusses each item
within the PN scheme and provides an initial reference to applicable sections within the manual.
DIGIT ITEM DESCRIPTION REFERENCE
19 Always '4' common starting digit for RC4000-based products
18 ACU Version K - RC4000 "x"- future variations
16,17 Mount Type 2 digits identifying unique mount/antenna software
support 3.1.5
15 Navigation Specifies optional navigation equipment (GPS,
Fluxgate Compass, etc) 3.1.5
14 Tracking Optional Inclined orbit tracking support 3.1.5
13 Remote Control Optional remote control (serial, IP-based, etc.) 2.1.2.2.4
12 Receiver 2 Receiver support (DVB, Beacon Receiver, etc.) 2.1.2.3.2
11 Receiver 1 Receiver support (Beacon Receiver, modem,etc.) 2.1.2.2.3
10 Enclosure Boardset Packaging (boardset only or included in
specific enclosure) 2.1
9 User Interface
8 Antenna Interface
7 RF Options Auxiliary RF routing board, etc. 2.1.2.3.8
6 Options Card DVB Heater, Relay usage, etc. 2.1.2.3
5 Motor Drive Card Specifies DC or AC power supply, etc. 2.1.2.1
4 Resolver Card Reserved for future support of resolver interface
3 Environmental Optional heaters, fans, conformal coating, etc.
2 Power Input Specify which power input option used
1 Reserved
0 Options
NOTE: the part numbering scheme is included in the manual to introduce various ways that the RC4000
boardset may be customized for a particular antenna application. The part numbering scheme is subject
to change. Consult RCI before ordering for detailed discussion of options available.

RC4000 ACU Boardset Chapter 2 Hardware
9
2.0 HARDWARE
This chapter describes both the RC4000 boardset and common external devices that may be used for
integrating an antenna system.
2.1 Boardset Devices
This section describes the mechanical and electrical interfaces of the boards that comprise the RC4000
boardset. NOTE: details on how the boardset is packaged in an enclosure and how interfaces are
connected to an antenna system would be detailed in Appendix C – Enclosure Specific Data.
2.1.1 Mechanical Mounting
The following picture shows a complete RC4000 boardset attached to a mounting plate.
The boardset is designed to occupy the minimum volume by placing the drive board on the bottom, the
computing board in the middle and the options board on top. The pictured stack includes an auxiliary RF
routing board (see 2.1.2.4.8) with four coaxial connectors on top. In this configuration, the dimensions of
the stack (including plate) are 7" x 6 1/16" x 3 3/4". With mating connectors and wiring, a stack of this
size fits within an enclosure with internal measurements of 8.9" x 7.4" x 3.4".

RC4000 ACU Boardset Chapter 2 Hardware
10
The boardset may be laid out in other configurations in order to accommodate additional components or
to minimize height. The following picture shows an alternative configuration. In this example the drive
and computing boards are stacked together with the options board to the side.
Note that the inclinometer could be mounted inside the enclosure if it rotates with the elevation axis
correctly (see section 2.2.1).

RC4000 ACU Boardset Chapter 2 Hardware
11
The following drawing shows the mounting hole spacing for the RC4000 boards. The Power/Drive board
and the Computing/Interface board utilize all nine mounting holes. The Options board (on top in first
picture) is narrower and only uses the six inner mounting holes.

RC4000 ACU Boardset Chapter 2 Hardware
12
The first picture shows the complete stack attached to a 6.0840" x 6.8667' mounting plate (M-4KPLT1)
built by RCI. In addition to board size, room for connectors, wiring harnesses, etc. should be considered.
The following diagram shows how a boardset stack could fit inside a chassis with inside dimensions of
7.32" x 8.8191".
NOTE: the RC4000 boardset may be purchased attached to the M-4KPLT1 plate.