Sea Tel 2406 User manual

Field Service Procedure - Replacement PCU Kit, 2406
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Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 
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1. BriefSummary:
TroubleshootingdocumentfordiagnosingafaultwithandreplacingthePCUassemblyonthe2406antennas.
2. Checklist:
VerifyInitialization
N0Parameter
PedestalError
TestMotor
3. TheoryofOperation:
ThePCUmotherboardcalculatesthemovementofthevesselbasedonthefeedbackfromsensorsinthelevelcageand
directionalchangesfromthevesselsgyrocompass.ThePCUusesthisdatatodrivethemotoroftherelevantaxistoan
equalandoppositeamountofmovementtothevesseltomaintainstabilization.Alongwithstability,thePCUalso
controlstheantennadishscanpattern.
Alltracking,targeting,pointingandpolarizationcommandsaresentfromtheDACtothePCU.Thesecommandsare
basedonthevessel’sGPSlocation,targetingcalculationsoroperatorinputs.ThePCUsoftwareconfiguresthefunction
ofthepedestalandiscalibratedbytheN0parameter.Thissetsthemotorgainsforeachaxisandthedishscanpattern
basedonthesizeoftheantenna.Thesesettingsareallstoredas“RemoteParameters”.
ShouldthePCUflagapedestalerror,furtherdiagnosticswillneedtobecompletedtoidentifywhichaxistheerroris
locatedinandalsothecomponent(s)whicharefaulty.Thisdocumentwillrunthroughdecodingthepedestalerror,then
furthertroubleshootingtherelevantaxistodiagnosewhichcomponent(s)aredefective.
4. VerifyInitialization:

Powercyclethepedestal.
1. Levelcagedrivestoitsendstopthendrivesto45degrees.
2. Elevationaxisdrivesto45degreesbasedonthelevelcage.
3. Crosslevelaxisdrivestolevelbasedonthelevelcageshorizonreference.
4. Unlimitedazimuthaxissystemsdriveclockwiseuntilthehomeflagandsensoralign.

IftheACUreportsmodel“xx03”thePCU’sN0parameterneedscalibrating.RefertothecalibratingthePCUsN0
Parametersectionofthisdocument.Failurestocompleteanyoftheinitializationsteps,orapedestalerror,require
furthertroubleshooting. 

Field Service Procedure - Replacement PCU Kit, 2406
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5. PedestalError(Error8):
5.1. DecodingaPedestalError.
WhentheDACdisplaysapedestalerror,enterintotheremotecommandwindowandenter“S0000”thenpress
Entertwice.TheerrorcodewillnowbedisplayedintheRemoteMonitorscreen.Decodethe4thcharacterofthe
errorcodefromthebelowtable:

@NoneKRef+LV+CLVStabLimit+AZ+LV
ACLLRef+AZWStabLimit+AZ+LV+CL
BLVMRef+AZ+CLXStabLimit+Ref
CCL+LVNRef+AZ+LVYStabLimit+Ref+CL
DAZORef+AZ+LV+CLZStabLimit+Ref+LV
EAZ+CLPStabLimit [StabLimit+Ref+LV+CL
FAZ+LVQStabLimit+CL\StabLimit+Ref+AZ
GAZ+LV+CLRStabLimit+LV]StabLimit+Ref+AZ+CL
HRefSStabLimit+CL+LV^StabLimit+Ref+AZ+LV
IRef+CLTStabLimit+AZ_StabLimit+Ref+AZ+LV+CL
JRef+LVUStabLimit+AZ+CL

5.2. ErrorTypes.
The3typesofpedestalerrorare....
1. ServoLimit–AservolimiterrormeansthePCUmotherboardisissuingthecommandtothemotor
driverPCBtodrivetherelevantaxisharderthanitshouldundernormaloperation(theservolimithas
beenreached).Thiscanoccurthroughstabilisationortargeting.
2. StabilityLimit–Astabilitylimiterrormeanstheantennahasmis‐pointedfromitsdesiredtarget
positionbymorethanhalfadegree.WhenastabilitylimiterrorisflaggedonaVSATantenna,theDAC
willsendaTXMutecommandtoinhibitthetransmitfunctionofthesatellitemodem;Itiscommonto
seetheservolimitandstabilitylimiterrorstogether.
3. AZReferenceError–Anazimuthreferenceerrormeanstheantennahasacorruptreadinginthe
relativescale.Ifthesystemislimitedazimuthitcouldbecausedbyithittingitsendstopundernormal
operation.Ifthesystemisunlimitedazimuthitcouldbecausedbytheantennacompletinga360
degreerotationwithoutthesensordetectingthehomeflag.Otherpossibilitiesaretheencoderfailing
oraphysicalproblemsuchasthebeltslippingonthemotorpulleyorthepulleyslippingonthemotor
shaft. 

Field Service Procedure - Replacement PCU Kit, 2406
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5.3. TroubleshootingPedestalErrors–ServoLimitandStabilityLimit.
1. Reinitializethepedestal;doesitdrivecorrectlyornotatall?Ifnoneoftheaxesdrive,verifytheN0and
motorgainparameters(N1=CL,N2=ELandN3=AZ)arecorrectlyconfiguredinthePCUthroughthe
RemoteCommandwindowoftheDAC.QuerybyNx999,where“x”istheaxisidentifier.
2. Verifythebalanceoftheantennaandcheckforphysicalrestrictionsonthepedestal–Iftheaxisisn’t
correctlybalancedthePCUwillbeoutputtingadditionaldrivecommandstomaintaintheantennas
levelandpointingpositions.
3. Themotorisn’tdrivingcorrectlyornomotordriveispresent,testthemotorforfaultsusingthebelow
procedure.Ifthemotorisdefectivereplaceitandthenretestthefunctionoftheantenna.Iftheaxisstill
failstodrivecorrectlythedefectivemotormayhavedamagedthemotordriverPCB.ReplacethePCU
assembly.
4. Anotherpotentialproblemcouldbeadamagedorintermittentharnessconnection.Removethe
harnessbackshellsandverifyallthepinsareseatedcorrectly.Checkcontinuityfrompintopin(endto
end)andalsoacrossthepins(ateachend)toverifythereisnoshortintheconnections.
5.4. TroubleshootingPedestalErrors–AzimuthReferenceError.
1. Ifthesystemislimitedazimuth,verifythattheantennadrivesclockwisetoitsendstopduring
initialization.Iftheantennaisunlimitedazimuth,reinitializeitandverifythatthesensordetectsthe
homeflagasthesystemdrivesclockwise.Ifthisstepfails,verifyifthemagnet/sensorispresentor
attempttomovethesensorclosertothemagnet.Failingthis,thesensororitsfeedbackhasfailed.
2. Drivetheazimuthaxisin90degreeincrementsandverifytheantennapointscorrectlyandthatthe
DACdisplaysthecorrectrelativeposition.Alsoverifythatthereisnophysicalrestrictiononthe
azimuthaxissuchasthebeltslippingonthemotorpulleyorthepulleyslippingonthemotorshaft.
5.5. TesttheMotor.
1. Checkcontinuitybetweenground(themotorconnectorbackshell)andthe3driveroutputsonpins1,2
and3oftheharness.
2. Nowcheckcontinuitybetweenpins4,5,6,7and8andtheground(themotorconnectorbackshell).
3. Alsocheckbetweentheindividualpins1,2and3andtherestofthepins(i.e.testpin1topin4,5,6,7
and8andsoon,notbetweenpins1and2,1and3or2and3).
4. Ifthereisanycontinuitymeasuredonthestepsmentionedabove,themotorisdefective.Ifthemotor
hasdrawnexcessivecurrentthenthereisapossibilitythemotordriverPCB(andpotentiallythePCU
motherboard)hasbeendamaged.Theantenna’soperationshouldbeverifiedwithareplacement
motor.Ifafterreplacingthemotortheantennaisstillnotoperational,replacethePCUassemblyasper
thefollowingprocedure. 

Field Service Procedure - Replacement PCU Kit, 2406
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6. HomeFlagOffset:
Ifanunlimitedazimuthantennahasbeeninstalledwithanoffsetfromthebowofthevessel,itispossibleahomeflag
offset(HFO)hasbeenstoredinthePCUtocorrecttherelativeposition.BeforereplacingaPCU,itisadvisabletoquery
theHFOparametertoverifyifitwillneedtobeconfiguredinthereplacementPCU.WhentheDACisshowing000.0
relative,theantennashouldbepointingtothebowofthevessel.ToquerytheHFO,combinetheparametercode“N6”
withthequerycode“999”andenter“N6999”intotheremotecommandwindowoftheDACandpresstheEnterbutton
Thiswillgiveyouthehomeflagoffsetvalue(000)willbedisplayedifthissettinghasn’tbeenconfigured.

7. ReplacingthePCUAssembly:
7.1. Tools.

2mmFlatBlade(Terminal)Screwdriver
#1PhillipsScrewdriver
Loctite242
7.2. Procedure.
Replacingthe2406PCUassembly,SeaTelkitpartnumber:137300(PCUassemblypartnumber:121185‐4).

*Caution:Powerdownthepedestalbeforefollowing
thisprocedure.
1.Usinga2mmflatbladescrewdriver,removeharness
connectionsfromthebackofthePCUand
2.DisconnecttheBNCconnectorfortheGPSantenna.



3.Usinga#1Phillipsscrewdriverremovethe4screws
attachingthePCUtotheazimuthpostandremovethe
assembly.Savethehardwareforfutureuse.


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
4.NowremovetheGPSantennafromthefaultyPCU
andattachittothereplacementPCUusingtheadhesive
padprovidedinthekitandsecuretheexcessharness
withtheP‐clips,applyingLoctite242tothethreads.



5.InstallthereplacementPCUandsecureittothe
azimuthpostusingthe4screwsandwashersremoved
earlier,usingLoctite242duringinstallation.
6.Re‐ConnecttheD‐subharnessconnectorsandthe
GPSantennasBNCconnector.
7.ConfigurethePCU’sN0parameter(asperthe
followingprocedure)andadjusttheremotetiltif
necessary.

8. Calibratingthe2406PCUsN0Parameter:
AsPCUscanbeusedacrossmodelranges,itisnecessarytoconfiguretheN0parameterofthereplacementPCUtothe
specificationofthepedestalitwillbeinstalledon.ThiswillsetthemotorgainsforCL(N1),EL(N2)andAZ(N3)andalso
configurethedishscanpattern(N7)forthesizeofthepedestalsreflector.
WithouttheN0parameterconfiguredinthePCUtheantennawon’tinitializeasnoneofthemotorgainswillbeset‐only
thelevelcagewilldrive.ThestatuswindowoftheDACwillalsodisplaythemodelnumberoftheantennaas“xx03”
opposedto2406.

PressandholdtheleftandrightarrowkeysontheDACtoenterintothesetupmenuandthenusethedownarrow
toscrollthroughthewindowsuntiltheremotecommandscreenisdisplayed.
EnterintotheremotecommandscreenandenterthecorrectN0parameterforthemodelofantennaasperthe
belowtable.I.e.theN0parameterfora2406is“017”.Youwouldenter“N0017”(“N0”forthesystemparameter+
“017”fortheantennamodel).
Savetheremoteparameters.
Cyclepowertothesystemtoreinitializethepedestal,verifyingtheN0hassavedandthesysteminitializes
correctly,displayingthecorrectmodelnumberontheDAConcetheinitializationhascompleted.
ModelN0N1N2N3N7
2406017020010012042
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9. CalibratingtheRemoteTiltSetting:
Thisprocedureisrequiredtocalibratethelevelcagesothatallthesensorswillbeaccuratelyalignedtotheiraxis.The
fluidfilledtiltsensorprovidesatwodimensionalhorizonreference.Thesystemisnotabletoautomaticallycalculatethe
exactcentervalue,thereforeitisnecessarytoperformthisproceduretomanuallyenteranyoffsetrequiredtomakesure
thePCUreceivesatruehorizonreference.

1. Turndishscanoff:
EnterintotheSetupMenubypressingandholdingthearrowstogetheruntiltheELTrimorAutoTrim
parameterisdisplayed.
Usethearrowkeytoscrollthroughthemenuuntilthedishscanwindowisdisplayed.
Pressthearrowtoactivatethewindowandthenpressthearrow,followedbythebuttontoturn
dishscanfromontooff.
*Note:Whenyoupressthearrowtoturndishscanoffyouwon’tseethedisplaychangeuntilyoupressthe
button.

(Steps2‐7requiresassistancetoobserveandoperateantennasimultaneously)

2. EnterintotheSetupMenubypressingandholdingthearrowstogetheruntiltheELTrimorAutoTrim
parameterisdisplayed.

3. PushthearrowkeyuntiltheRemoteTiltwindowisdisplayed.

4. PushthearrowkeytoactivatetheRemoteTiltsetting.

5. Usethearrowkeystopositionthebubbleasclosetothecenteraspossible.Eachpressofanarrowkeyonthe
directionalpadwillmovetheRemoteTilt½adegree.Itisadvisedthatyouonlypressthebuttononceandwaitfor
theaxistomovebeforepressingitagain.

Whenstandingbehindtheantennalookingatthebubble,ifthebubbleisovertotheright,youneedtopressthe
(right)arrowtobringthebubbleintothecenter.Ifthebubbleisdowntowardsyou,youneedtopressthe
(down)arrowtobringittowardsthecenter.Ifthebubbleistotheleft,youneedtopressthe(left)arrowandif
thebubbleisuptowardsthetop,youneedpressthe(up)arrowtomoveittowardsthecenter.
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Whencorrectthebubbleshouldbeasclosetothecenterofthefluidaspossible

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6. WhenthebubbleisascentralaspossiblepressthebuttontodeactivatetheRemoteTiltsetting.

7. Turndishscanon:
EnterintotheSetupMenubypressingandholdingthearrowsuntileithertheELTrimorAutoTrim
parameterisdisplayed.
Usethearrowkeytoscrollthroughthemenuuntilthedishscanwindowisdisplayed.
Pressthearrowkeytoactivatethewindowandthenpressthearrowkey,followedbythebuttonto
turndishscanfromofftoon.
*Note:Whenyoupressthearrowtoturndishscanonyouwon’tseethedisplaychangeuntilyoupressthe
button.

8. SavetheRemoteTiltsettinginthePCU:
PressthearrowkeyuntiltheRemoteParameterswindowisdisplayed.
Pressthearrowkeytoactivatethewindowfollowedbythebutton(you’llseeaconfirmationonthe
displaysaying“Saved”).

9. AsgoodpracticemakeanoteofyourN4andN5parametersonceyouhavecorrectlysettheremotetilt.TheN4and
N5parametersareanumericreadoftheremotetilt.Todothisgototheremotecommandwindowandkeyin
N4999toreadtheCLsetting,followedbyN5999toreadtheELsetting.


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