Sea Tel 6003A User manual

Field Service Procedure – Replacement Level Cage Motor Kit, XX04 &
6003A/6004
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Document No
135290 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levelcagemotorontheXX04and6003A/6004
seriesantennas.
2. Checklist:
VerifyInitialization
VerifyPointing
VerifyTargeting
3. TheoryofOperation:
ElevationdriveoccursfromoffsettingthelevelcagewhichintroduceserrorintothePCU’scontrolloop,theelevation
motorwillthendrivetheaxistobringthelevelcagebacktolevel,removingtheerrorandinturnchangingtheelevation
lookangleoftheantenna.Ifthelevelcagemotorisdefectiveitwillpreventthesystemfromtargetingthecorrect
elevation,bynotoffsettingthelevelcagethecorrectamountandthereforecausingtheelevationtargetingerror.
Asignthatthelevelcagemotorisfaultyisthesystemkeepsfindingthesatelliteatdifferentelevationpositionsandthe
trimsneedadjustingtocompensateforthis.Anotheristhesystemmis‐pointscompletelyandthelookangleofthe
antennadoesn’tcorrespondwiththevaluedisplayedontheDAC.Whatisactuallyhappeningisthemotorisn’toffsetting
thelevelcageproperly,thereforethesystemisn’ttargetingcorrectlyTheDAC,however,willdisplaythedesiredtarget
positionasthereisnolivefeedback.
4. VerifyInitialization:

Powercyclethepedestal
1. Levelcagedrivestoitsendstop,thenbacksoffexactly45degrees
2. Elevationaxisdrivestolevelbasedonthelevelcage’shorizonreference
3. Crosslevelaxisdrivestolevelbasedonthelevelcage’shorizonreference
4. Limitedazimuthsystemsdriveclockwiseintotheazimuthendstop,thenbackoffto630degreesof
relative
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Verifyifthelevelcagemotordrivescorrectly,ifnotthenthesystemwon’ttarget45degreesofelevationduringthe
initializationprocess.
IftheACUreportsmodel"xx03/xx04",theantennasN0parameterneedscalibratingandverifyingthatthePCUsavesit
correctly.Adriveissueorpedestalerror(error8)requiresfurthertroubleshooting.
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Field Service Procedure – Replacement Level Cage Motor Kit, XX04 &
6003A/6004
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
Document No
135290 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. 

5. VerifyPointing:
Drivetheantennathroughoutitselevationrangeandverifyitpointscorrectly.Target0,45&90degrees,makingsure
thereflectorisatthecorrectpositiondisplayedontheDAC.
6. VerifyTargeting:
Iftheantennaappearstopointcorrectlyamoreaccuratewaytoverifythisistoseeifitcanrepeatedlytargetthecorrect
elevationofasatellite.Trimthesystemtothecorrectelevationandthenpointtheantennaawayfromthesatellite.Now
targetthedesiredsatelliteandverifythesystemtargetstowithin0.5degreesofthecorrectelevation.
Anyerrorintheabovestepsisanindicationthelevelcagemotorisdefective.
7. TesttheMotor:
Thesteppermotorcanbeverifiedbymeasuringresistanceacrossthefollowingconnections:

Pin1to3=38ohm
Pin2to3=38ohm
Pin5to4=38ohm
Pin6to4=38ohm
Pin1to2=76ohm
Pin5to6=76ohm


Ifoneofthemeasuringpointsisopen(noresistance)themotorisdefectiveandneedstobereplaced.Alsomeasurefrom
allthepinstoground(themetalcaseofthemotor)theymustbeopen,notshorted.
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Field Service Procedure – Replacement Level Cage Motor Kit, XX04 &
6003A/6004

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
Document No
135290 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. 

8. FurtherInformation:
Nowthemotorhasbeenreplacedverifythesysteminitializesproperly,hasthecorrectrangeofmotionandtargetsthe
correctelevationvalues(iftheelevationtrimwasadjustedbecauseofthetargetingerrorthiswillneedresetting).
IfthetargetingissuestillpersiststhereisthepossibilitythatthedriverforthelevelcagemotoronthePCUmotherboard
hasfailed.TestthefourtransistorsonthePCUmotherboardfordamageasperthebelowimage.


Setyourmulti‐metertotheDiodesettingandtestbetweenthepinsofthetransistorsasperthefollowing
procedureandverifytheresults.

Pins1(+)and2(‐)=LO
Pins1(+)and3(‐)=0.66V(+/‐0.03)
Pins1(‐)and3(+)=LO
Pins1(‐)and2(+)=0.66V(+/‐0.01)
Pins3(‐)and2(+)=0.66V(+/‐0.01)
Pins3(+)and2(‐)=LO

2

13

AnyreadingsshortedtogroundoroutoftheabovetolerancesmeanthetransistorisdefectiveandthePCUneedstobe
replaced(ifthisisthecaseit’spossibletheoriginalmotorisnotdefective).
Ifthesystemisdisplayingapedestalerror(error8)thenthereisadriveissuewiththeantennaandattentionwillneedto
bepaidtothemotorandmotordriverfortherelevantaxis.
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Field Service Procedure – Replacement Level Cage Motor Kit, XX04 &
6003A/6004
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Document No
135290 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. 

9. ReplacingtheLevelCageMotor:
9.1. Tools.

2mmFlatBlade(Terminal)Screwdriver
#1PhillipsScrewdriver
#2PhillipsScrewdriver
½”Wrench/Spanner
Loctite222,242and638

9.2. Procedure.
Procedureforreplacingthelevelcagemotor,SeaTelpartnumber:124115‐2(levelcagemotorpartnumber:116059‐
2).

*CAUTION:Powerdownthepedestalbeforefollowingthis
procedure.
1.Usinga2mmflatbladescrewdriverloosentheretainingscrews
fromtheD‐subconnector&removethereferenceharnessfromthe
levelcage.
2.Usinga#1Phillipsscrewdriverloosen(don’tfullyremove)the4
screwssecuringthelevelcagemotorandpushthemotortowards
thelevelcage.
3.Nowusinga½”wrenchundotheNylocknutandremovethe
levelcageassembly.
4.Usinga#2Phillipsscrewdriverremovethefourscrewsattaching
theELpancovertothePOLAUXRelayassembly(oneoftheseis
locatedbehindthelevelcageasshown)andremovethesixscrews
&twoP‐clampsattachingtheouterELpancovertotheinsideEL
pancover.



6.SlidetheELPancovertotheleft&carefullyremoveittoexpose
thelevelcagemotorwiringharness&disconnecttheIDCconnector
frommotorterminationPCB.
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Field Service Procedure – Replacement Level Cage Motor Kit, XX04 &
6003A/6004
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
Document No
135290 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. 

7.Usinga#1Phillipsscrewdriverremovethefourscrewssecuring
themotortotheELpan&savethehardwareforfutureuse.
8.ApplyLoctite638totheshaftofthereplacementmotorandfit
thepulleyinthesamepositionastheoneonthedefectivemotor.
FitthesetscrewsintothepulleywithLoctite222.
*Note:ForfurtherinformationrefertotheLoctiteProcedure
121730providedwiththiskit.
9.InstallthereplacementlevelcagemotorintotheELpanwiththe
beltaroundthesprocketandlooselysecurethemotor.

10.ConnecttheIDCconnectorintothemotorterminationPCB&
re‐InstalltherightELpan.
11.ApplyLoctite242tothehardware&reinstallall10screws
makingsurethelonger2screwsareusedontheP‐clipswhich
securethereferenceharness.
12.Refitthelevelcage,aligningitsendstopssoithas90degreesof
rotationfromhorizontaltovertical.InstalltheNylocknutremoved
earlierandconnectthereferenceharnessintotheD‐subconnector,
tighteningtheretainingscrewsusinga2mmflatbladescrewdriver.

13.Verifythelevelcagehas90degreesofmovementwithoutthe
referenceharnessbeingpulledtaught.
14.Tensionthebeltbyslidingthemotorassemblybyhandaway
fromthelevelcage&tightenoneofthefourscrews.

15.Increasethebelttensionuntilthebeltcanonlybeeasilytwisted
just¼turnwithyourfingers.
16.Ifthebelttensionistootight/loose,adjustuntilcorrect&then
securethemotor.
17.Ifthebelttensioniscorrecttightenthe3loosescrews.

