Sea Tel 4012 User manual

Field Service Procedure – Replacement ICU PCB Kit, 4012
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Document No
136831 Rev A
Copyright © Sea Tel, Inc 2012 - The information contained in this document is proprietary to Sea
Tel, Inc. This document may not be reproduced or distributed in any form without prior written
consent of Sea Tel, Inc. 

1. BriefSummary:
TroubleshootingdocumentfordiagnosingafaultwithandreplacingtheICUmainPCBonthe4012antenna.
2. Checklist:

VerifyInitialization
ICUStatusLED
PedestalError
VerifyStabilization/SensorFeedback
Communications(EoC)
PolDrive
3. TheoryofOperation:
TheICUPCBisnowasingleintegratedcomponentwhichcontainsthemainPCB,trackingreceiver,coaxswitchand
abovedeckcommunicationscapability.ADE/BDEcommunicationsarehandlednowbyEthernetoverCoax(EoC)with
diagnosticLEDstoverifythefunction.
Stabilization,targetinganddrivecommandsarecalculatedbytheICUbasedonfeedbackfromthesensorsonthe
motionplatformPCB,headingchangesfromthevesselsgyrocompass,targetcommandsbasedonthevesselsGPS
locationanddesiredsatelliteaswellasinputsfromtheoperatorandtrackingdecisionsbasedonthehighestsignal
strength.
AfterdrivecommandshavebeenissuedorfeedbackfromthesensorsonthemotionplatformPCBhavebeencalculated
basedonvoltagechangeovertimetocalculatetheforcesexertedonthesystemtheICUPCBwillsendthecommandto
themotordriverenclosure(MDE)whichinturnwilldrivethebrush‐lessDCmotor(BLDC)todrivetherelevantaxisan
equalandoppositeamounttotheforcebeingexertedonthesystem.
L‐BandIFsignalsarefedintothetrackingreceiverwhichisnowintegratedintotheICU(asopposedtobeinginstalledin
thebelowdecks)shorteningthedistanceofthereceivepathandofferinghighersignalstrengththanpreviousdesigns.
ThreecoaxcoaxialconnectionsarealsointegratedontothePCBforthereceiveoutputtotherotaryjointandbelow
decks(alongwiththeEoC)aswellastwoinputsfromboththeX‐PolandCo‐PolLNBs.
4. VerifyInitialization:

Powercyclethepedestal
1. 24VDCissuppliedtothemotorsbrakestoreleasethem,then12VDCholdsthemopen
2. Elevationaxisdrivesto45degreesbasedontheICU’shorizonreference
3. CrosslevelaxisdrivestolevelbasedontheICU’shorizonreference
4. Unlimitedazimuthaxiswilldriveclockwiseuntilthehomeflagandsensormakecontact
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Ifanyofthesestepsfailverifythatthe4012’sProfile1settingisconfiguredcorrectlyandsavestotheICU.Adriveissue,
pedestalerrororerrorLEDwillrequirefurthertroubleshooting.
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Field Service Procedure – Replacement ICU PCB Kit, 4012
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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. 

5. ICUStatusLEDDiagnostics

AstatusLEDisinstalledontheICUmainPCBandcanbeviewedfromtheundersideoftheICUassembly.Thedifferent
colorsstatusesindicate:

SolidGreen

ICUstatusisgood.


SolidRed

ICUfaultdetection.OperationalsoftwarewillneverleavethestatusLEDsolidRED.Reprogram

theICUsoftware.ReplacetheICUmainPCB.

SolidOrange

Softwareupdatetothe

ICU

mainPCB

isinprocess.
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BlinkingOrange
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Softwareupdatetothemotor

driverenclosure(throughthe

ICU)isinprocess.


BlinkingRed
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Communicationerrorwiththemotordriverenclosure.ChecktheMDEstatusLEDs.IfMDEis

good,checktoassurethattheharnessconnectionsareseatedproperly.Checkharness
connections(pin‐pin,wire‐wireandwire‐ground)forgoodcontinuity.ReplacethemainPCB.
ReplacetheMDE.
6. PedestalError(Error8):
6.1. DecodingaPedestalError.
Forthe4012antennaiftherederrorLEDisilluminatedontheMXPenterintothe“system”screenand
selecttheerroricontoviewthedisplayederror(s).
6.2. ErrorTypes.
The3typesofpedestalerrorare.....
1. ServoLimit(CL,LVandAZ)–AservolimiterrormeanstheICUmainPCBisissuingthecommandto
themotordriverenclosuretodrivetherelevantaxisharderthanitshouldundernormaloperation(the
servolimithasbeenreached).Thiscouldbewhiletheantennaistryingtomaintainitspointingangle,
orwhiletheantennaisdrivingtheaxistoatargetposition.
2. StabilityLimit–Astabilitylimiterrormeanstheantennahasmispointedfromitsdesiredpositionby
morethanhalfadegree.WhenastabilitylimiterrorisflaggedonaVSATantennatheMXPwillsend
theTXMutecommandtoinhibitthetransmitfunctionofthesatellitemodem(It’scommontoseethe
servolimitandstabilitylimiterrorstogether).
3. AZReferenceError–Anazimuthreferenceerrormeansthereisacorruptreadingintheantennas
relativescale.Thiscouldbecausedbythesystemcompletinga360degreerotationwithoutthesensor
comingintocontactwiththehomeflag,thesensorcomingintocontactwiththehomeflagtooearly,
oraphysicalproblemsuchasthechainslippingonthemotorpulleyorthepulleyslippingonthemotor
shaft.
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Field Service Procedure – Replacement ICU PCB Kit, 4012
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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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6.3. TroubleshootingPedestalErrors–ServoLimitandStabilityLimit.
1. Reinitializethepedestal;doesitdrivecorrectlyoratall?IfnoneoftheaxisdriveverifytheN0orProfile
settingisconfiguredcorrectlyforyourmodelofantenna.
2. Verifythebalanceoftheantennaandcheckforphysicalrestrictionsonthepedestal–Iftheaxisisn’t
correctlybalancedtheICUwillbeoutputtingadditionaldrivecommandstomaintaintheantennaslevel
position.
3. Ifthemotorisn’tdrivingcorrectlyornomotordriveispresent,testthemotorforfaultsusingthebelow
procedure.Ifyoufindthemotorisdefectivereplaceitandthentestthefunctionofthemotordriver
enclosure.Iftheaxisstillfailstodrivecorrectlythemotormayhavedamagedit.Replacethemotor
driver.
6.4. TroubleshootingPedestalErrors–AzimuthReferenceError.
1. Reinitializethesystemandverifythesensorcomesintocontactwiththehomeflagasthesystem
drivesclockwiseinazimuth(theLEDwillilluminate).Ifnotverifyifthehomeflag/sensorispresent,if
correctthenthereisasensor/feedbackfailure.
2. Drivetheazimuthaxisin90degreeincrementsandverifythattheantennapointscorrectlyandthat
theMXPdisplaysthecorrectrelativeposition.Alsoverifythatthereisnophysicalrestrictiononthe
azimuthaxissuchasthechainslippingonthemotorpulleyorthepulleyslippingonthemotorshaft.
7. TestTheMotor:
Checkcontinuitybetweenground(themotorconnectorbackshell)andthe3driveroutputsonpins1,2and3of
theharness.
Nowcheckcontinuitybetweenpins4,5,6,7,8andtheground(themotorconnectorbackshell).
Alsocheckbetweentheindividualpins1,2,3andtherestofthepins(i.e.testpin1topin4,5,6,7,8andsoon,
notbetweenpins1and2,1and3or2and3).
Ifthereisanycontinuitymeasuredonthestepsmentionedabove,themotorisdefective(whichwouldbe
highlightedbythediagnosticLEDsontheMDE).Theantennasoperationshouldbeverifiedwithareplacement
motor.Ifnormaloperationdoesn’treturntheMDE/ICUwillrequirefurthertroubleshooting.
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Field Service Procedure – Replacement ICU PCB Kit, 4012
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consent of Sea Tel, Inc. 
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8. VerifyStabilization:
Thepurposeofthisprocedureistophysicallymovethesystemsaxisunderstaticconditions,introducingerrorintothe
ICU’scontrolloop,andthenverifythesystemisabletoreturntoitslevelposition(stabilizeitself).Thesetestscanbe
performedbymonitoringthesensoroutputsusingDacRemPorthe4012graphsscreenandbyphysicallymovingthe
antennaandobservinghowitresponds.

1. TurntrackingoffandopentheDISP_VscreenofDacRemPoraccessthegraphsscreenofthe4012GUI.The
softwarewillnowplotthelevelpositionoftheLVandCLMEMsensors.Observeforanyabnormalities.
2. VerifyCrossLevelresponse:
Standingbehindthesystem,pushthecrosslevelbeamdowntotheleftandholditinposition.VerifythattheCL
tracemovesdownanequalamounttothemovementexertedontheaxis.Releasetheaxisandverifythatthetrace
andsystemaxisbothreturnbacktotheiroriginalpositionsinstantly,withoutdeviatingortakingtimetosettle.
Nowpushthecrosslevelbeamdowntotherightandholditinposition.VerifythattheCLtracemovesupanequal
amounttothemovementexertedontheaxis.Releasetheaxisandverifythetraceandsystemaxisbothreturn
backtotheiroriginalpositionsinstantly,withoutdeviatingortakingtimetosettle.
3. VerifyLevel(Elevation)response:
Pushthereflectorupinelevationandholditinposition.VerifythattheLVtracemovesdownanequalamountto
themovementexertedontheaxis.Releasetheaxisandverifythetraceandsystemaxisbothreturnbacktotheir
originalpositionsinstantly,withoutdeviatingortakingtimetosettle.Pushthereflectordowninelevationandhold
itinposition.VerifythattheLVtracemovesupanequalamounttothemovementexertedontheaxis.Releasethe
axisandverifythetraceandsystemaxisbothreturnbacktotheiroriginalpositionsinstantly,withoutdeviatingor
takingtimetosettle.
4. Inthetraceshouldlooksimilartothebelowimage.Notehowaftereachmovementthesystemreturnstoitslevel
positionefficientlywithouttakingtimetosettle.Shouldthesystemtaketimetosettle,ornotstabilizetothe
originalposition(notnecessarilyontheredline)thenthisisanindicationthattheantennaisn’tmaintainingits
horizonreferencecorrectlyandfurthertroubleshootingwillneedtobeundertaken.
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Field Service Procedure – Replacement ICU PCB Kit, 4012
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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. 

9. RateSensorMonitoring:
RatesensoroutputscanalsobemonitoredusingtheDISP_WscreenofDacRemPorfromthegraphsscreenofthe4012
GUItoverifyanydeviationsunderstaticconditions.Thetracesshouldremainconsistent;anydriftingorspikesarean
indicationthesensorsvoltageoutputischangingandthesensorisdefective(providednoforcesarebeingexertedonthe
system).

10. AzimuthTargeting:
Shouldtheantennahaveissuestargetinginazimuth,suchasnotaccuratelyfindingthesatelliteorrepeatedlyfindingthe
satelliteindifferentazimuthpositions,thenit’simportanttodiagnoseifthesystemismispointinginazimuthorrelative.
Relativefeedbackfromtheazimuthencodercanbeverifiedbyinitializingthesystem,verifyingitcalibratesitself
correctly,andthendrivingthepedestalclockwisein90degreeincrementsovera360degreerotation.Notethatthe
systempointscorrectlyrelativetothevesselandthatnoazimuthreferenceerrorisflaggedbytheICU.Amechanical
problemsuchasthebeltslippingonthesprocketcouldalsocausethiskindoferror.
Ifthesystemkeepsfindingthesatelliteatdifferentazimuthpositionsbutatthesamerelative,thentheencoderis
functioningcorrectlyandtheazimuthratesensoriscalculatingthemovementincorrectlycausingtheantennato
mispoint.
11. Drift:
Ifaratesensoris“drifting”itsnominalvoltageoutputhaschangedfromthecorrect2.5VDC.Thiswillcauseerrorinthe
axiscontrolloopandcausetheantennatomove.Itismorecommontoseethisdriftintheazimuthaxisasthecrosslevel
andelevationaxisbothhavealongtermreference,providedbythetiltsensor.However,shouldtheratesensorsdriftbe
largeenough,itcanover‐compensatethetiltsensorandthesystemwilldriveintooneofthecrosslevelorelevationend
stops.
Toverifyifthesystemisdriftinginazimuth,turntrackingoffandmonitortherelativeposition.Understaticconditions,
whenthevesselsheadingisunchanged,therelativecountshouldremainstationary.Iftherelativevaluebeginsto
changefromitscurrentposition,theazimuthratesensorisdrifting,introducingerrorintotheaxiscontrolloop.
IftheratesensorsarecheckedasOK,ashipsgyrocaninducedrift.ThiswillintroducelooperrorintotheICUcontrolloop
andcausetheantennatodrift.Ifit’ssuspectedtheheadingiscausingtheantennatodriftthesystemcanbesetto
satellitereferencemodetouncouplethegyrocompassfromthecontrolloop.
*Note:IftheICUandgyrocompassaredisplayingthesameheadingreadingthisisn’tanindicationthattheheading
valueiscorrect,onlythattheICUisreadingtheinformationcorrectly. 

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12. VerifyPolDrive:

AsthepolauxrelayisintegratedintotheICUmainPCBafaultwiththepolalignmentcouldpotentiallybecausedbythis
PCB.Ifnopoldriveispresentsetthepolsettingtomanualandapplydrivetothefeedassemblyandmeasurethevoltage
tothemotorontheIDCconnector,24VDCshouldbepresent.Ifvoltageispresentbutthemotorisn’tdrivingthemotoris
defectiveandneedsreplacing.Ifnovoltageispresentverifytheconnectionsofthereflectorharnessbymeasuringpinto
pinasperthebelowdiagram.

Iftheharnessconnectionsaregood,thentheICUmainPCBoutputtingthevoltagetodrivethemotorandneeds
replacing.
AslongasthepolrangeiswithinthepotlimitstheICUwillissuethe24VDCtodrivethepolmotorbasedontheantenna
targeting,achangeinthevesselsGPSpositionoroperatorinputs.TheICUmainPCBwilldrivethepolmotor,whichwill
rotatethefeedassemblyuntilthecorrectoutputfromthepothasbeenreceived.Atwhichpointthefeedwillbeinthe
optimumreceptionposition(providingthesystemisfunctioningandcalibratedcorrectly).Thereforethereisalsothe
possibilityforapoldrivefaulttobecausedbytheICUmainPCB.
13. CommunicationDiagnostics(EoC):
TheMXPandICUbothcontainadiagnosticLEDtoverifythestatusofthesystemscommunications.OneoftheEoC
(EthernetoverCoax)LEDswillblinktoverifythestatusofthecommunicationsbetweentheADEandBDE.Basedon
whichunit(MXPorICU)hassenttheverificationcommandwilldependonwhichoneoftheEoCLED’sisblinking,if
neitheroftheLEDsareblinkingthenfurtherdiagnosticsneedstobeundertaken.


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
14. ReplacingtheICUmainPCB:
14.1. Tools.

5/16”Wrench/SpannerorSocket
2mmFlatBlade(Terminal)Screwdriver
Apairof7/16”Wrenchesofa7/16”WrenchandSocket
#1PhillipsScrewdriver
3/16”Socket
Loctite248

14.2. Procedure.
ProcedureforreplacingtheICUPCB,SeaTelkitpartnumber:136818(ICUPCBpartnumber:133368‐1).

*Caution:Powerdownthepedestalbeforefollowingthis
procedure.
1.DisconnecttheGPSantennasRJ‐45connectorfrom
theICU.



2.DisconnecttheACpowerinputsocketfromtheICU.


3.DisconnecttheRFpowerconnectionfromtheICU.


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
4.Disconnectthe3SMAcablesfromtheICUusinga
5/16”wrench.


5.Usinga2mmflatbladescrewdriverdisconnecttheD‐
subconnectorsfromtheICU.


6.Usingapairof7/16”wrenches(orawrenchandsocket)
undothe4setsofhardwaresecuringtheICUtothe
elevationpanandremovethedefectiveICU.Savethe
hardwareforfutureuse.
*Note:DuetoweightoftheICUremovingitwillaffect
thebalanceofthepedestal.Supportthesystemincross
levelastheICUisremoved.


7.Usinga#1Phillipsscrewdriverremovethe11screws
securingthelidoftheICU.Savethehardwareforfuture
use.


8.Usinga3/16”socketremovethestandoffssecuringthe
J6,J7,J9andJ10D‐subconnectors.Savethehardware
forfutureuse.


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consent of Sea Tel, Inc. 


9.Usinga5/16wrenchorsocketremovethe3setsof
hardwarefromthesocketconnectorsfortheLNBsand
rotaryjoint.Savethehardwareforfutureuse.


10.Usinga7/16”wrenchdisconnecttheright‐handF‐
connectorfromthetrackingreceiver.
*Note:Theleft‐handconnectorcanbeleftattached



11.DisconnecttheribboncablesfromtheICUmainPCB.


12.DisconnecttheDCpowerIDCconnectorfromtheICU
mainPCB.


13.Usinga#1Phillipsscrewdriverremovethescrews
securingtheICUPCBmountingbrackettotheenclosure
andremovethePCBassembly.Savethehardwarefor
futureuse.


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consent of Sea Tel, Inc. 


14.RemovethedefectivePCBfromthemounting
bracketusinga#1Phillipsscrewdriverandinstallthe
replacementPCBtothebracket,applyingLoctite248to
thethreads.


15.InstallthereplacementPCBassemblyintotheICU
enclosureusingthenewhardwareprovidedinthekit.
ApplyLoctite248tothethreads.


16.ConnecttheDCpowerIDCconnecttothe
replacementPCB.


17.ConnecttheribboncablestothereplacementPCB.


18.ConnecttheF‐connectortothetrackingreceiveron
thereplacementPCB.


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consent of Sea Tel, Inc. 


19.Installthestandoffsremovedinstep8totheJ6,J7,J9
andJ10D‐subconnectors.
*Note:It’sadvisabletodotheseupfingertightto
preventdamagingthesmallthreads.


20.Usinga5/16”wrench/socketinstallthehardware
removedinstep9tosecuretheSMAconnectorstothe
ICUenclosure.


21.ReinstallthecovertotheICUenclosureusingthe
hardwareremovedinstep7.ApplyLoctite248tothe
threads.


22.InstalltheICUassemblyusingthehardwareremoved
instep6,applyLoctite248tothethreadsandsecure
usingapairof7/16”wrenchesorawrenchandsocket.


23.ConnecttheACpowerconnectortotheICU.


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
24.ConnecttheRFpowerconnectortotheICU.


25.ConnecttheSMAcablestotheICUwiththeorangeX‐
polIFcableintothe“LNBA”port,theyellowCo‐PolIF
cableintothe“LNBB”portandtheBlackRXIFcableinto
the“RJ”port.Asshownintheimageontheright.


26.ConnecttheD‐subconnectorstotheICUusinga
2mmflatbladescrewdriver.
27.ConnecttheGPSantennasRJ‐45connector.

