Sea Tel Coastal 24 User manual

Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
Torque, Coastal 24 & 30
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Document No
135396 Rev A
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hi‐torqueelevationmotorwithencoderonthe
Coastalseriesantennas.
2. Checklist:

InitializethePedestal
VerifyDrive/Motor
VerifytheEncoderFeedback
3. TheoryofOperation:
TheHi‐TorqueelevationsteppermotorontheCoastal20,24and30antennasfeaturesanintegratedencoderfor
feedbackintothePCUoftheelevationlookangleofthesystem.Duringtheinitializationprocessthesystemdrivesdown
inelevationuntilthereflectorcomesintocontactwiththeendstop,atthispointtheelevationpositioniscalibrated&
theencoderwillcountelevationincrements/decrementsaccordingly.
AfterinitializationthesystemwilltargettheelevationlookangleforthedesiredsatellitebasedonthevesselsGPS
location.Oncethesatellitehasbeenacquired,elevationdrivewillbeissuedtocounteractthevesselsmovement&
maintainstabilizationbasedonfeedbackfromtherateandtiltsensorsonthePCUmotherboard.Oncethetracking
functionoftheantennaisenabledelevationdrivewillalsobeissuedtooptimizethereceivesignallevel,basedon
feedbackfromeachdishscanrevolution.
4. InitializethePedestal:
Cyclethepowertothepedestalbytogglingtheon/offswitchonthefrontpaneloftheDACPcontrolunit.Duringthe
initializationprocessthecontrolpanelwilldisplay“initializing”,theelevationmotorwilldrivethereflectordownintoits
endstopatwhichpointtheencoderwillbecalibrated.Thenextstepwillbetheelevationmotorwilldrivethereflectorto
45degrees.Observethesystemandverifytheelevationdriveissmoothandthatthereflectorisphysicallypositionedat
45degrees.
Ifthedriveisn’tsmoothit’spossiblethatthemotorhasafaultandthemotorwillrequirefurtherdiagnostics.Shouldthe
elevationaxisnotpointat45degreesduringtheinitializationprocessthenit’spossibletheencoderisdefectiveand
furtherdiagnosticsarerequired.


Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
Torque, Coastal 24 & 30
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Document No
135396 Rev A
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theDriveoftheElevationAxis:
Drivefromtheelevationmotorshouldbeconsistent;rollingthesystemwillcausethePCUtoissuedrive(thiscanbe
donebyremovingtheradometop,unboltingthesystemfromitsmountingpointandrollingthedomebasefromfront
toback).Observethemotorandverifyifit’sfunctioningcorrectly.Ifthemotorskipsinsteadofdrivingsmoothlyit’s
possibleawindinghasfailedorifnodriveispresentitspossiblethereisashortinthemotor.
Ifitissuspectedthereisadeadspotinthemotorpowerdownthesystemandgentlyrotatetheaxisbymovingthebelt
backwardsandforwards.Thisinturnwillrotatethemotorpulleyandshaftanditshouldbeapparentifthereisadead
spotastherotationwillfeeltaughtatthatposition.
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*Caution:Beextremelycarefulrotatingthepedestalaroundwhileyourfingersareinthisareato
preventpinchingorcrushingyourfingersinthepedestalassembly.


Anotherindicationthatthesystemisn’tdrivingcorrectlyisiftheunwraplightisilluminatedonthecontrolpanel,yetthe
elevationpositionisn’tchanging,thisusuallyindicatesthatthemotorcan’tdriveinelevation,thereforeisn’tsearching
correctlyandinturntheelevationfeedbackfromtheencoderisn’tmoving(theotheroptionistheencoderisdefective).
6. RuntheBuilt‐InTest(BIT):
CoastalPCUsoftware2.06andabovesupportsabuiltintestfunctionusedtoisolateproblemswithcomponentsinthe
antennasystem.ToruntheBITtestpowerofftheantennabypressingthePowerbuttononthecontrolpanel,nowpress
andholdtheNextbutton,andthenpressthePowerbutton.Asopposedtoinitializingthecontrolpanelwillnowdisplay
“BuiltInTestNexttoBegin”.
PressingtheNextbuttonwillrunautomaticallyuntilcompleted,ifnofaultsarefoundwiththesystem“BITFinishedNo
Errors”willbedisplayedorunlessaanerrorisdiscoveredthetestwillpausewhilethespecificerrorishighlighted,this
shouldberecordedforfurtherdiagnostics.Pressingnextwillcontinuetorunthetest.Anyerrorsrecordedrequirefurther
diagnosticsasperthebelowinformation.
6.1. AnaloguetoDigitalConvertorTest.
ThistestchecksforbasiccommunicationwiththeAnalogue‐to‐DigitalConverteronthePCUmainboard.A
badA/Dcouldmakeallothertestsfail.
“TestingADC”willbedisplayedasthetestruns.AnErrorcode1.01‐1.08willbedisplayedifoneofthese
testsfails.Ifanytestfails,replacethePCUandre‐runBITtests.
6.2. DigitaltoAnalogueConvertorTest.
ThistestchecksthebasicintegrityoftheDigital‐to‐AnalogueConverteronthePCUmainboardbylooping
backoneofitsoutputstotheD/A.
“TestingDAC”willbedisplayedasthetestruns.AnErrorcode2.01‐2.21willbedisplayedifoneofthese
testsfails.Ifanytestfails,replacethePCUandre‐runBITtests.


Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
Torque, Coastal 24 & 30

Page3of9

Document No
135396 Rev A
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. 

6.3. AzimuthMotorDriveTest.
Thistestcheckstheabilityofthemotordrivertodrivecurrentthroughtheazimuthmotor.Thecurrentto
themotoriscontrolledbyaPWMcircuit.ThePWMcurrentisrepeatedlysampledandstatisticallyanalyzed
duringthistest.
“TestingAZMTR”willbedisplayedasthetestruns.AnErrorcode3.01‐3.17willbedisplayedifoneofthese
testsfails.
Afailureindicatesadefectivemotor,motordriverPCBorharness.Temporarilyconnectasparemotorto
thePCUinplaceofthefailedmotor(orswaptheazimuthmotorwiththepolmotorconnectionatthePCU)
toisolatethefailuretothePCUormotor.Thenre‐runthesametest.
Ifthetestpasses,replacethefailedmotor(ifyouswappedtheazimuthandpolmotorconnectionsandthe
polmotortestdidnotfail)andreruntheBITtests.
Ifthetestfails,replacethePCUandre‐runtheBITtests.

6.4. ElevationMotorDriveTest.
ThistestcheckstheabilityofthemotordrivertodrivecurrentthroughtheElevationmotor.Thecurrentto
themotoriscontrolledbyaPWMcircuit.ThePWMcurrentisrepeatedlysampledandstatisticallyanalyzed
duringthistest.
“TestingELMTR”willbedisplayedasthetestruns.AnErrorcode4.01‐4.17willbedisplayedifoneofthese
testsfails.
Afailureindicatesafailedmotor,motordriverPCBorharness.Temporarilyconnectasparemotortothe
PCUinplaceofthefailedmotor(orswaptheelevationmotorwiththeazimuthmotorconnectionatthe
PCU)toisolatethefailuretothePCUormotor.Thenre‐runthesametest.
Ifthetestpasses,replacethefailedmotor(ifyouswappedtheelevationandazimuthmotorconnections
andtheazimuthmotortestdidnotfail)andreruntheBITtests.
Ifthetestfails,replacethePCUandre‐runtheBITtests.
6.5. POLMotorDriverTest.
Thistestcheckstheabilityofthemotordrivertodrivecurrentthroughthepolmotor.Thecurrenttothe
motoriscontrolledbyaPWMcircuit.ThePWMcurrentisrepeatedlysampledandstatisticallyanalyzed
duringthistest.“TestingPOLMTR”willbedisplayedasthetestruns.AnErrorcode5.01‐5.17willbe
displayedifoneofthesetestsfails.
Afailureindicatesafailedmotor,motordriverPCBorharness.Temporarilyconnectasparemotortothe
PCUinplaceofthefailedmotor(orswapthePOLmotorwiththeAZmotorconnectionatthePCU)to
isolatethefailuretothePCUormotor.Thenre‐runthesametest.
Ifthetestpasses,replacethefailedmotor(ifyouswappedmotorstheothermotortestwillnotfail)and
reruntheBITtests.
Ifthetestfails,replacethePCUandre‐runtheBITtests.


Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
Torque, Coastal 24 & 30

Page4of9
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Document No
135396 Rev A
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. 

6.6. SensorTest.
Thistestchecksfornullsensoroffsetsforalevel,motionlesssystem.Thecheckshavefairlywidepass/fail
criteria,butcanstillfailifpedestalisinmotionoroutoflevelmorethanafewdegrees.
“TestSensorBias”willbedisplayedasthetestruns.AnErrorcode6.01‐6.05willbedisplayedifoneof
thesetestsfails.Ifanytestfails,replacethePCUandre‐runBITtests.
6.7. AzimuthMove/RateSensorTest.
Thistestcommandmovesthedishatvariousspeedsinazimuthandcheckstheresultsusingtheazimutrh
ratesensor.“TestAZSensor”willbedisplayedasthetestruns.AnErrorcode7.01‐7.05willbedisplayedif
oneofthesetestsfails.Anerrorindicatesamotordriverateorsensorfailure.Thiscouldbedueto:
1. Mechanicalbindingofthepedestalortheazimuthbearing‐Withthepoweroff,visuallyinspectthe
antennaandradome(insideofbaseandtop)fordragagainsttheradomeorbinding/foulingofpedestal
intheantennacablesoragainstthecableconnectorbracket.Rotatetheantennainazimuthbyhandto
feelforanybindingintheazimuthaxis.Re‐routecablesand/orbendconnectorbrackettoremove
foulingwiththepedestal.Ifthepedestalisdragginginsidetheradomeitselforiftheazimuthbearing
hasfailed,theradomeand/orpedestalwillhavetobereplaced.Ifthischeckfoundaproblemandyou
havecorrectedit,re‐runtheBITtests.
2. Azimuthbeltdragging,orslipping‐Inspecttheazimuthdrivebeltforchaffingorwear(leavesblack
dust).Inspecttheazimuthdrivebeltforpropertension(beltshouldbetaughtwhenpinchedinonboth
sidesoftheazimuthmotordrivesprocket,itshouldnotflexmorethan1/16thinchonbothsideswhen
pinched.Re‐alignandtensionthemotorforcorrectbeltpathandtension.Ifthischeckfoundaproblem
andyouhavecorrectedit,re‐runtheBITtests.
3. Azimuthmotorfailure‐Replacetheazimuthmotorandre‐runtheBITtests.
4. Azimuthdriveorazimuthratesensorfailure‐ReplacethePCUandre‐runtheBITtests.
6.8. PolPot/MotorMoveTest.
ThistestmovesthefeedassemblyatvariousspeedsinPolarizationandcheckstheresultsusingthePOL
potentiometer.“TestPOLAssy”willbedisplayedasthetestruns.AnErrorcode8.01‐8.07willbedisplayed
ifoneofthesetestsfails.Afailureindicatesafailedmotor,beltorpotentiometer.Thiscouldbedueto:
1. Mechanicalbindingofthepolarizationassembly‐Withtheantennapowereddown,visuallyinspectthe
polarizationassembly(includingLNBandcables)fordragagainstthepedestalordish.Rotatethe
polarizationassemblybyhandtofeelforanybindinginrotation.Re‐routecablestoremovefouling
withthepedestal.Ifbindingisfelt,removemotorbeltandre‐checkbinding.Ifthepolarization
assemblyisstillbinding(indicatingbearingfailure)itmustbereplaced.Ifthischeckfoundaproblem,
andyouhavecorrectedit,re‐runtheBITtests.


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2. Poldrivebeltorpolpotdrivebeltdraggingorslipping‐Inspectdrivebeltsforchaffingorwear(leaves
blackdust).Inspectthedrivebeltspropertension(beltsshouldbesemi‐tautwhenpinchedinonboth
sidesofthemotordrivesprocketorpotdrivesprocket.Thebeltsshouldnotflexmorethan1/16thinch
onbothsideswhenpinched).Re‐alignandtensionthemotorandpotforcorrectbeltpathandtension.
Ifthischeckfoundaproblem,andyouhavecorrectedit,re‐runtheBITtests.
3. Rotatethepolarizationassemblytocenterofitsmechanicalrange(LNBvertical)andobservewhileBIT
testruns.Ifthepolmotordoesnotdriveduringthetest,replacethepolmotorandre‐runtheBITtests.
Ifthepolangpotentiometer(polpot)ismountedoutofpositionorhasfailed,rotatethepolarization
assemblytothecenterofitsmechanicalrange.Loosenpotmountingbrackettode‐couplethebeltand
rotatethepotsprocket.Ifthesprocketislooseontheshaftofthepot,tightenthesetscrews.Ifthepot
doesnotrotate,replaceit.
Checkcontinuityofthepotfromthewiperandboththeclockwiseandcounter‐clockwisecontacts.
Clockwisetocounter‐clockwiseendsandviceversa,asteadyresistancefrom0–5or5–0ohmsshouldbe
measured(dependingonthedirectionofrotation)fromwipertoclockwise,orcounter‐clockwise,toverify
properoperation.Thepotisathreeturnpotentiometer,rotatethesprockettofindoneendstopandthen
rotateitexactly1½turnsawayfromthatstoptothecenterofrotation.Holdthesprocketinplacewhile
re‐couplingthebelt,tensionthebeltasyoutightenthepotmountingbracket.Ifthischeckfounda
problem,andyouhavecorrectedit,re‐runtheBITtests.

Checktheharnessforgoodcontinuityfrompoint‐to‐pointandthattherearenoshortsfromwire‐to‐wire
orfromwire‐to‐groundthatarenotsupposedtobethereaspertheabovediagram.Repairanyharness
problemsfoundandre‐runtheBITtests.Iftherearenoproblemswithanyofthestepsabove,replacethe
PCUandre‐runtheBITtests.

Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
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consent of Sea Tel, Inc. 
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7. VerifytheEncoderFeedback:
Ifthesysteminitializeswiththedisplayonthecontrolpanelreading45degreesofelevation,yetthereflectorisata
differentangle,thenit’spossiblethattheelevationendstopisintheincorrectpositionandiscalibratingtheencoder
positionincorrectly.Movethereflectorbyhanddowntotheendstop,thedisplayonthecontrolpanelshouldread0;
nowverifythatthereflectorisphysicallypointingat0degreesofelevation.Ifnotadjusttheelevationendstopuntilthe
reflectorinitializesat0&testthefunctionoftheencoder.
Ifthereflectorisphysicallyat0degreesofelevationwhenthesysteminitializes,physicallymovethereflectorbyhandto
differentelevationpointsandverifythattheelevationpositiononthecontrolpaneliscorrectinrelationtothelookangle
ofthereflector.Theelevationpositingshouldalsoincrement/decrementsmoothlyastheaxisisrotatedwithoutjumping
orskipping.Anyfailureoftheabovestepsmeanstheencoderisdefectiveandthemotorassemblywillneedtobe
replaced.
AnothertestwhichcanbeperformedistopowerdownthesystemanddisconnecttheencoderharnessfromthePCU.
Whenreinitializedtheantennawillcountthestepsofthesteppermotortogaugetheelevationlookangleandthe
elevationpositiononthecontrolpanelwillbeacalculatedvalve(asopposedtoliveencoderfeedback).Ifafter
disconnectingtheencodertheantennaoperatescorrectlytheencoderisdefectiveandthemotorassemblywillneedto
bereplaced.


Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
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consent of Sea Tel, Inc. 
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8. ReplacingtheElevationMotor:
8.1. Tools.

Snips/Cutters
#1PhillipsScrewdriver
1/16”AllenWrench/Key
CableTies/TieWraps
Loctite222,242and638

8.2. Procedure.
ProcedureforreplacingtheelevationmotorontheCoastal20,24and30antennas,SeaTelkitpartnumber:125228‐1
(motorpartnumber:125519).


*Caution:Powerdownthepedestalbeforefollowingthis
procedure.

1.Usinga#1Phillipsscrewdriverremovetheground
connectorfromthebodyofthemotor,savethehardwarefor
futureuse.


2.DisconnecttheIDCconnectorfromtheencoderonthe
elevationmotor.


3.Snipthecabletiessecuringtheelevationmotorandencoder
harness.


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consent of Sea Tel, Inc. 
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
4.Usinga#1Phillipsscrewdriverremovethetwoscrews
securingtheelevationmotorconnectortothePCU.Savethe
hardwareforfutureuse.


5.Usinga#1Phillipsscrewdriverremovethe4screwssecuring
themotortoitsbracket.Holesallowingaccessareinthe
elevationpan,thesystemwillneedtoberotatedinelevation
toalignthem.


6.Installthepulleytothereplacementmotorinthesame
positionasonthedefectivemotor.ApplyLoctite638tothe
shaftofthemotorandinstallthesetscrewwithLoctite222
usinga1/16”Allenwrench.Ensurethesetscrewisinstalled
againsttheflatedgeofthemotorshaft.Savethehardwarefor
futureuse.
*Note:ForfurtherinformationrefertotheLoctiteProcedure
121730providedwiththiskit.


7.Installthereplacementmotorassemblywithharnessexiting
awayfromtheantennausingthehardwareremovedinstep5.
ApplyLoctite242tothefourscrewsbutdonotfullytightenat
thistime.



8.Pressurethemotorawayfromthemaindrivesprocketand
tightentwoofthescrews.Verifythebelttensionandifcorrect
tightenthetworemainingscrews,ifnotrepeattheprevious
stepuntilthetensioniscorrect.


Field Service Procedure – Replacement EL Motor Kit, W-Encoder, Hi-
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consent of Sea Tel, Inc. 
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
9.Verifythealignmentbetweenthetwosprocketsiscorrect
andthebeltrunsstraight;rotatethesystemupanddownin
elevationtoverifythesystemmovesfreely.Failureofthisstep
isdowntoimproperalignmentofthemotorpulley.


10.Reinstalltheencoderharnessandgroundconnectionto
themotorassemblyusingthehardwareremovedinstep1.


11.ReconnecttheelevationmotorharnesstothePCU,
ensuringthesplitwashersareinstalled(noneedtoLoctite).


12.Securetheelevationmotorharnessandencoderharness
withcableties.

