Sea Tel 6003A User manual

Field Service Procedure – Pol Motor Kit, 6003A/6004
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
Document No
135282 Rev B
Copyright © Sea Tel, Inc 2011 - 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polmotoronthe6003Aand6004series
antennas.
2. Checklist:
VerifyRangeofMotion
VerifyPotRange
MeasureMotorVoltage
VerifyHarness
3. TheoryofOperation:
Theantennasfeedassemblyisdriventhroughits180degreerangeofmotionbya24VDCsteppermotorforthecorrect
orientationofthelinearsignal.BasedonthevesselsGPSpositionandthelookangletothedesiredsatellitetheDACwill
calculatethenumericalvalueforthepositionofthepolassembly,thePCUwillthensendthecommandtothePOLAux
relaytoissuevoltagetodrivethepolmotoruntilthepolpotoutputsthecorrectvalueatwhichpointthefeedwillbe
alignedtothepolarityofthesatellitesignal(provideditsbeencalibratedcorrectly).ThenasthevesselsailsandtheGPS
positionchangesthelookangletothesatellitewillalsochangeandadjustmentswillbemadetomaintaingoodcrosspol
isolation(alignmenttothesatelliteslinearsignal).
Anindicationthatthereisafaultwiththefeedalignmentofthesystemisthetargetlightwillbepermanently
illuminatedontheDACandtheantennawon’ttargetcorrectly,sitting8degreesabove(or8degreesbelowathigh
elevationlookangles)thesatelliteselevationlookangle.Aspartoftheantennastargetingprocedurethesystemwill
targetabove(orbelow)thesatellite,calculatetheautothresholdsettingbasedonthenoisefloorlevelandthenalignthe
feedforthecorrectreceptionpositionbasedonthevesselsGPSpositionandthelookuptableintheDACbefore
targetingthesatellite.
Ifthesystemisunabletodrivethepolmotorsothecorrectfeedbackisreceivedfromthepotorthepothasfailedand
won’tgivethecorrectfeedbackthesystemcan’tcompletethetargetingprocessandtheantennawillstay8degrees
aboveorbelowthedesiredtargetpositionofthesatellite.Settingthepoltypeto“0009”willmaketheantennatargetby
removingtheautopolfunctionfromthetargetingprocess;howeverthemissalignmentofthefeedwillcausebadcross
polisolation.
4. VerifyRangeofMotion:
FirstlyverifythesettingsintheDACarecorrect,thepolscaleshouldbesetto“0090”togivethefeed180degreesof
motionandthedefaultpoloffsetsettingis“0030”.
SetthepoltypesettinginthesetupmenuoftheDACto“0009”tochangethemodeofthepolassemblyfromautomatic
(poltype“0072”)tomanual.ThisremovestheautomaticcalculationbasedonthevesselsGPSpositionandallowsthe
feedassemblytobemanuallydrivenfordiagnosticpurposes.Nowenterthepolwindowanddrivethepolassembly
downintoitsendstop,observethepositionofthefeed.Nowdrivethepolassemblyup,thefeedshouldmove180
degreesundernormaloperation.
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Field Service Procedure – Pol Motor Kit, 6003A/6004
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Document No
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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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5. VerifyPotRange:
IfnofeeddriveispresentverifythepolreadingontheDAC,isn’toutofrange(i.e.displayingavalueofeither0or255).If
oneofthesevaluesaredisplayedit’spossiblethepotisn’talignedcorrectlyandthatadjustingitmaybringitbackto
withinthescaletheDACrecognizes.Backthepotofffromthemaingearsprocketandrotateitspulley,verifyingifthe
feedbackchangesontheDAConcethepothasbeenrealigned.Ifsocalibratethepolpotandverifyoperationas
describedinthelaterstagesofthisdocument.
IfthepolcountontheDACdoesn’tchangewhenthepotisadjustedthepothasfailedandisoutputtingadefaultvalue,
nodrivewillbeissuedtothepolmotorasthevalueisoutoftherangewhichthesystemoperatesin.Thenthepolpot
mustbechanged.
6. MeasuretheMotorVoltage:
Leavingthepoltypeinmanualmode,applydrivetothefeedassemblyandmeasurethevoltagetothemotorontheIDC
connector,12VDC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polauxrelayPCBisn’toutputtingthevoltagetodrivethemotorandneeds
replacing,shouldthisnotrectifytheissuethenit’spossiblethePCU,ortheinterfaceharnessisatfault.
WhentheantennaisinautopolaslongasthepolrangeiswithinthepotlimitstheDACwillissuethepoldrivecommand
tothePCUmotherboard,basedontheantennatargeting,achangeinthevesselsGPSpositionoroperatorinputs.The
PCUmotherboardwillthenissuethecommandtoswitchthepolauxrelaytodrivethepolmotor.Themotorwillthen
drivethefeeduntilthecorrectoutputfromthepothasbeenreceived,atwhichpointthefeedwillbeinthecorrect
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PCUmotherboard.
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Field Service Procedure – Pol Motor Kit, 6003A/6004
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Document No
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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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
7. Replacingthe24VDCPolangMotorAssembly:
7.1. Tools.

Snips/Cutters
11/32”Wrench/Spanner
#1PhillipsScrewdriver
1/16”AllenWrench
Loctite222,242&638

7.2. Procedure.
Procedureforreplacingthe6003A/6004polangmotorusingSeaTelkitpartnumber:124108‐1(polmotorpartnumber:
124069‐1).

*CAUTION:Powerdownthepedestalbeforefollowingthis
procedure.
1.FirstlysetthepoltypesettingintheDACto“0009”(manualpol).

2.Usingapairofsnipscutthecabletiessecuringthepolmotor
harness.
3.NowremovethepolmotorsIDCconnectorfromtermination
blockPCBconnectionblockonthefeedassembly.



4.Usingan11/32”wrenchundothetwonutssecuringthepolmotor
assemblytothefeedandremoveit.

5.Usingthehardwaresuppliedinthekitbuildthereplacementpol
motorassemblyinthesameconfigurationasthedefectiveone.
ApplyLoctite242totheboltssecuringtheplatetothemotor&to
theoutermountingthreads.
6.Securethepulleytothemotorshaftinthesamepositionand
orientationasonthedefectivemotor,applyingLoctite638tothe
motorshaft&Loctite222tothesetscrew,tightenwitha1/16”
Allenwrench.
*Note:ForfurtherinformationrefertotheLoctiteProcedure
121730providedwiththiskit.

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Field Service Procedure – Pol Motor Kit, 6003A/6004
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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. 


7.Installthemotortothefeedassembly,applyLoctite242tothe
mountingthreadsandtightenthesecuringnuts.



8.ConnecttheIDCconnectortotheterminationblockandsecure
theexcesscablewithcableties.




8. PolAlignmentandVerification:
1. DrivethereflectortozerodegreesofelevationtoviewtheorientationoftheLNB:
PressthebuttontoturntheTrackingfunctionoff(ifapplicable)topreventtheantennafromgoingintoa
search.Pushthebuttonuntilthe‘Antenna’windowisdisplayed(thescreenwillshowtheAZ,ELandREL
values).Pressthebuttontwicetoisolatethe‘EL’windowandthenpressthearrowtoactivateit(acursor
willbedisplayed).Nowusetheandarrowkeystoscrollthecursoralongandusetheandarrowkeys
tochangetheelevationvalueto“00.0”andpressthebutton.
2. SetPolTypetomanualmode:
Enterthe‘SetupMenu’bypressingandholdingthearrowkeystogetheruntilthe“ELTRIM’windowis
displayed.Pushthearrowkeyuntilthe‘PolangType’windowisdisplayed.Pressthearrowkeytoactivate
thewindow.Nowusetheandarrowkeystoscrollthecursoralongandusetheandarrowkeysto
changethecharacters.Setthe‘PolangType’to“0009”whichismanualmodeandpressthebutton.
3. PressthebuttontogotoPolOffsetwindowandverifythedefaultsettingis“0030”.(Ifnecessaryusearrow
keystoselectappropriatedigitsandchangeaccordingly).
4. Nowkeeppressingthebuttonuntilthe‘Antenna’windowisdisplayed(thescreenwillshowtheAZ,ELand
RELvalues).
5. Pressthebutton4timesuntil‘POLxxx’isdisplayedandthenpressthearrowkeytoactivatethewindow.
*Note:It’sadvisabletohavesomeonewatchingthefeedwhilethepolisdriven.DrivingtheLNBpastitsnormal
rangeofoperationcancausedamagetotheassembly.
6. NowholdeithertheorarrowkeytorotatethePoluntilacountof“115”isdisplayed.


Field Service Procedure – Pol Motor Kit, 6003A/6004
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Document No
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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. 


7. ObservethephysicalalignmentoftheLNB:
Itshouldbehorizontalpointingdownwards.Ifnotcontinueontostep8,otherwiseskipaheadtostep12.


(Steps8‐12requiresassistancetoobserveandoperateantennasimultaneously)

8. UsingtheDAC‐2202drivethefeedassemblytovertical:
PressthearrowkeytoactivatethecursoronthePOLwindow.Nowholdeithertheorarrowkeytodrive
thePolangleuntiltheLNBisalignedverticallyfacingdownwards(alignthecenteroftheLNBwiththelowerfeed
strut).Nowpressthebuttontode‐activatethewindow.
9. LocatethePolPotonthefeedandloosenthescrewthatsecurestheslottedmountingplate(fig.1.1)witha3/32”
AllenwrenchandthencarefullymovethePolPotgearoutofalignmentwiththemaindrivengear(Fig.1.2).

(Fig.1.1)(Fig.1.2)
10. Alignthepotentiometer:
OntheDACverifythecursorisnotdisplayedonthePolwindow,ifitispressthebutton(Fig1.3)failuretodo
thiswillresultindisplaynotchanging.Nowrotatethepotmanuallyuntilacountof115isdisplayed.Nowreinstall
thePOTonthemainsprocket(Fig1.4).
*Note:Whenre‐installingthepotontothemainsprocketitscommonforthereadingtochangeastheteethofthe
sprocketsareengaged.Becauseofthisthetoleranceis+/‐2degreesso113‐117counts.

(Fig1.3)    (Fig1.4)
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Field Service Procedure – Pol Motor Kit, 6003A/6004
Page6of6
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Document No
135282 Rev B
Copyright © Sea Tel, Inc 2011 - 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. 
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11. DrivethePolangtoitsupperandlowerelectricallimitsandverifytheassemblydrivesinthecorrectdirectionand
thatthefeedassemblyhas180degreesofrotation:
OntheACUpressthe arrowkeytodisplaycursorunderneathPolvalue.Pressandholdthearrowkeyto
drivethefeedtoitsupperendstopandverifytheLNBishorizontalwiththecoaxcabletowardstheleft.ThePol
valueshouldbeapproximately211counts.
NowpressandholdthearrowkeytodrivethefeedtoitslowerendstopandverifytheLNBishorizontalwith
thecoaxcablestowardstheright.ThePolvalueshouldbeapproximately28counts.
12. IntheDACsetupmenu,gotothePolTypeparameterandsetantennabackintoAutoPolMode:
Pressandholdthearrowkeystogetheruntilthe‘ELTrim’or‘AutoTrim’windowisdisplayed.Pushthe
arrowkeytoscrollthroughthesettingsuntilthe‘PolangType’windowisdisplayedandpressthearrowkeyto
activatethewindow.Nowusetheandarrowkeystoscrollthecursoralongandusetheandarrow
keystochangethevaluefrom“0009”to“0072”andthenpressthebuttontoputthesystembackinto
AutomaticPolang(AutoPol)mode.
WatchtheLNBandverifyitreturnstothecorrectreceptionposition(whilethePOLmotorisdrivingthetargetlight
willbeilluminatedontheDAC).

13. SavethesettingsintheDAC‐2202:
Pressandholdthearrowkeystogetherbriefly,“SaveNewParameters”willbedisplayed.Pressthe
arrowkeytoactivatethewindowandthenpressthebutton,“ParametersSaved”willbedisplayedandthe
poltypeandpoloffsetwillbestoredintheDAC.