ViaSat 3862 User manual

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Model 3862
Autotrack Digital Controller
Operation and Maintenance Manual
Manual Part No. 1000569
January 2003
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Notice
All Rights Reserved
The information contained in this document is proprietary to ViaSat, Inc.
This document may not be reproduced or distributed in any form without
the consent of ViaSat, Inc.
The information in this document is subject to change without notice.
ViaSat, Inc. assumes no responsibility for any errors that may appear in
this document and does not warranty any specific application.
Any product names mentioned herein are used for identification purposes
only, and may be trademarks and/or registered trademarks of their
respective companies.
In all correspondence with ViaSat, Inc. regarding this publication, please
refer to the Manual Part No. on the title page.
Copyright ® 2003 ViaSat, Inc.
All rights reserved. No part of this book may be reproduced in any form
or by any means without permission in writing from ViaSat, Inc.
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Table of Contents
Table of Contents
Table of Contents .................................................................................................. iii
List of Figures ......................................................................................................viii
List of Tables .......................................................................................................... ix
Safety Summary ......................................................................................................x
General Information ........................................................................................... 1-1
1.1 Introduction .............................................................................................................1-1
1.2 Contents of this Manual .........................................................................................1-1
1.3 Use of this Manual ..................................................................................................1-1
1.4 Format of this Manual ............................................................................................1-2
1.5 Change Recommendations ....................................................................................1-2
1.6 Description ...............................................................................................................1-2
1.6.1 Major Components .................................................................................................1-3
1.6.2 Functional Configurations .....................................................................................1-3
1.6.3 Physical Configurations .........................................................................................1-4
1.7 Specifications ...........................................................................................................1-6
1.8 Glossary of Symbols and Abbreviations..............................................................1-7
Installation............................................................................................................ 2-1
2.1 Introduction .............................................................................................................2-1
2.2 Unpacking and Inspection.....................................................................................2-1
2.2.1 Damage or Loss During Shipment .......................................................................2-1
2.3 Equipment Return...................................................................................................2-1
2.4 Installation Procedure ............................................................................................2-2
2.4.1 General......................................................................................................................2-2
2.4.2 Chassis Slide Mounting..........................................................................................2-2
2.4.3 Cable Connectors ....................................................................................................2-3
2.4.4 Host Computer Interfaces....................................................................................2-16
2.4.4.1 Serial Communications ........................................................................................2-16
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Table of Contents
2.4.4.2 IEEE-488 Communications ..................................................................................2-16
2.4.5 Time-stamped Position and Autotrack Status Message..................................2-18
2.4.6 GPS Time-code Interface......................................................................................2-20
2.4.7 Power Input ...........................................................................................................2-20
2.5 Initial Checkout .....................................................................................................2-20
2.5.1 Initial Turn-on and Checkout..............................................................................2-21
2.5.2 Axis Position Offsets.............................................................................................2-24
Operation.............................................................................................................. 3-1
3.1 Introduction .............................................................................................................3-1
3.2 Modes of Operation ................................................................................................3-1
3.2.1 Local Pedestal Control............................................................................................3-1
3.2.2 Remote Control........................................................................................................3-2
3.2.3 Front-panel Control ................................................................................................3-2
3.3 Front-panel controls and indicators .....................................................................3-2
3.3.1 Liquid Crystal Display Indicators.........................................................................3-4
3.3.2 Data Entry ................................................................................................................3-5
3.3.3 Softkeys.....................................................................................................................3-6
3.3.4 Top Level Softkey Menu ........................................................................................3-6
3.3.5 Front-panel Operating Procedures .......................................................................3-6
3.3.6 Power Up And Down.............................................................................................3-6
3.3.7 Emergency Shutdown ............................................................................................3-8
3.3.8 Standby Mode..........................................................................................................3-8
3.3.9 Position Mode..........................................................................................................3-8
3.3.10 Rate Mode ................................................................................................................3-9
3.3.11 Track Mode ..............................................................................................................3-9
3.3.12 Menus .......................................................................................................................3-9
3.3.13 Softkey Axis Assignment .......................................................................................3-9
3.3.14 Secondary Modes ..................................................................................................3-10
3.3.14.1 Standby Mode........................................................................................................3-10
3.3.14.2 Scan Mode ..............................................................................................................3-11
3.3.14.3 Slave Mode.............................................................................................................3-11
3.3.14.4 Stow Mode .............................................................................................................3-11
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Table of Contents
3.3.15 Setup Menus ..........................................................................................................3-12
3.3.15.1 Servo Parameters...................................................................................................3-12
3.3.15.1.1 Digital Filter Selection ..........................................................................................3-12
3.3.15.1.2 Torque Bias Parameters........................................................................................3-14
3.3.15.1.3 Test Port Signal Selection .....................................................................................3-14
3.3.15.1.4 Step Response Test................................................................................................3-15
3.3.15.2 Scan Parameters ....................................................................................................3-16
3.3.15.2.1 Sector Scan..............................................................................................................3-17
3.3.15.2.2 Step Scan.................................................................................................................3-17
3.3.15.2.3 Spiral Scan ..............................................................................................................3-18
3.3.15.3 Position Parameters ..............................................................................................3-18
3.3.15.4 Limit Parameters ...................................................................................................3-19
3.3.16 Control Menus.......................................................................................................3-20
3.3.16.1 Local/remote Control...........................................................................................3-21
3.3.16.2 Autotrack Mode ....................................................................................................3-22
3.3.16.3 Steptrack Mode......................................................................................................3-24
3.3.16.4 AGC Channel Input..............................................................................................3-25
3.3.16.5 Digital Controller Setup Configuration Store/recall .......................................3-26
3.3.16.6 Feed Scan Selection ...............................................................................................3-28
3.3.16.7 Time And Date Set ................................................................................................3-29
3.3.16.8 Status And Command Lines................................................................................3-29
3.4 Remote operation ..................................................................................................3-30
Principles of Operation ...................................................................................... 4-1
4.1 Introduction .............................................................................................................4-1
4.2 Functional description............................................................................................4-1
4.2.1 Servo Assembly .......................................................................................................4-7
4.2.2 Synchro/resolver Assembly..................................................................................4-8
4.2.3 Operator/remote Interface Assembly................................................................4-10
4.2.4 Autotrack Assembly (Optional)..........................................................................4-11
4.2.5 Resolver Reference Oscillator Assembly ...........................................................4-12
4.2.6 Synchro Reference.................................................................................................4-13
4.2.7 Analog Rate Loop Assembly (Optional)............................................................4-13
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Table of Contents
4.2.7.1 Loop Compensation..............................................................................................4-13
4.2.7.2 Differential Tach/torque Bias (dual Drive System) .........................................4-13
4.2.8 Motherboard ..........................................................................................................4-14
4.2.9 Front Panel .............................................................................................................4-14
4.2.10 Front-panel Board Assembly...............................................................................4-15
Maintenance......................................................................................................... 5-1
5.1 Introduction .............................................................................................................5-1
5.2 Preventive Maintenance.........................................................................................5-1
5.2.1 Visual Inspection.....................................................................................................5-1
5.2.2 Cleaning....................................................................................................................5-2
5.3 Test Equipment........................................................................................................5-2
5.4 Troubleshooting ......................................................................................................5-2
5.5 Alignment.................................................................................................................5-6
5.6 Repair........................................................................................................................5-6
5.6.1 Prerequisites To Removal And Installation.........................................................5-7
5.6.2 Internal Component Access...................................................................................5-7
5.6.3 Servo, Synchro/resolver, ORI, Or Autotrack Board Removal..........................5-7
5.6.4 Servo, Synchro/resolver, ORI, Or Autotrack Board Installation .....................5-8
5.6.5 Resolver Reference Board Removal......................................................................5-8
5.6.6 Resolver Reference Board Installation .................................................................5-9
5.6.7 Power Supply Removal........................................................................................5-10
5.6.8 Power Supply Installation....................................................................................5-10
5.6.9 Power Inverter Removal ......................................................................................5-10
5.6.10 Power Inverter Installation ..................................................................................5-11
5.6.11 Optical Encoder Removal ....................................................................................5-11
5.6.12 Optical Encoder Installation ................................................................................5-12
5.6.13 Fan Assembly Removal........................................................................................5-13
5.6.14 Fan Assembly Installation....................................................................................5-13
Parts List ............................................................................................................... 6-1
6.1 Introduction .............................................................................................................6-1
6.2 Parts List and Assembly Drawings ......................................................................6-1
6.2.1 Explanation of Title Block on Parts Listing .........................................................6-1
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Table of Contents
6.2.2 Explanation of Parts Lists Column Headings .....................................................6-1
6.3 Ordering Parts .........................................................................................................6-2
Drawings .............................................................................................................. 7-1
7.1 Introduction .............................................................................................................7-1
7.2 Drawing Index.........................................................................................................7-1
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Table of Contents
LIST OF FIGURES
Figure 1.1. 3860 Digital Controller........................................................................................................1-2
Figure 1.2. 3860 Digital Controller Functional Configurations ........................................................1-5
Figure 2.1. Typical Slide Mounting ......................................................................................................2-2
Figure 2.2. Typical Rear-panel Connector Interface..........................................................................2-6
Figure 3.1. 3860 Digital Controller Front Panel.............................................................................3-3
Figure 3.2. LCD Controls And Indicators .......................................................................................3-5
Figure 3.3. Top Level Softkey Menu.................................................................................................3-7
Figure 3.4. Softkey Axis Assignment ...............................................................................................3-9
Figure 3.5. Secondary Modes............................................................................................................3-10
Figure 3.6. Servo Parameters ...............................................................................................................3-13
Figure 3.7. Scan Parameters ..............................................................................................................3-16
Figure 3.8. Position Parameters........................................................................................................3-19
Figure 3.9. Limit Parameters.............................................................................................................3-20
Figure 3.10. Control Menus...............................................................................................................3-21
Figure 3.11. Local/remote Control Selection ...............................................................................3-22
Figure 3.12. Autotrack Mode Parameters..........................................................................................3-23
Figure 3.13. Steptrack Mode Parameters ..........................................................................................3-24
Figure 3.14. AGC Channel Input Parameters ..............................................................................3-25
Figure 3.15. Digital Controller Setup Configuration Store/recall..........................................3-27
Figure 3.16. Feed Scanner Control...................................................................................................3-28
Figure 3.17. Time And Date Set .......................................................................................................3-29
Figure 4.1. 3860 Digital Controller Block Diagram, Single-chassis Configuration ........................4-3
Figure 4.2. 3860 Digital Controller Block Diagram, Two-chassis Configuration...........................4-5
Figure 4.3. Servo Assembly Block Diagram ........................................................................................4-7
3862 Autotrack Controller viii
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Table of Contents
Figure 4.4. Synchro/resolver Assembly Block Diagram ...................................................................4-9
Figure 4.5. Operator/remote Interface Assembly Block Diagram.................................................4-10
Figure 4.6. Autotrack Assembly Block Diagram ..............................................................................4-12
LIST OF TABLES
Table 1-1. Series 13000 Pedestal Technical Specifications .................................................................1-4
Table 1-2. Environmental Specifications.............................................................................................1-5
Table 4-1. Position Data Package Electrical Interface .......................................................................4-4
Table 4-2. Gearmotor Electrical Interface ...........................................................................................4-6
Table 5-1. Tools and Test Equipment..................................................................................................5-1
Table 5-2. Periodic Maintenance Chart ...............................................................................................5-2
Table 5-3. Routine Inspection ...............................................................................................................5-2
Table 5-4. Consumable Materials List .................................................................................................5-6
Table 5-5. Troubleshooting Chart ........................................................................................................5-7
Table 5-6. Finish Repair Consumable Materials ................................................................................5-9
Table 7.1. Drawing Index......................................................................................................................7-1
3862 Autotrack Controller ix
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Safety Summary
SAFETY SUMMARY
These are general safety precautions that are not related to
any specific procedure. These are recommended precautions
that personnel must understand and apply.
WARNING
Use care when using metal tools that circuits are not shorted.
Some circuits have high current capacity which, when shorted,
will flash and may cause burns and/or eye injury.
Remove all jewelry and exposed objects from body and
clothing before performing maintenance, adjustments, and/or
troubleshooting. Before working inside equipment, remove all
power, unless power is required to be on to perform
procedures. Do NOT replace parts or modules with power
ON.
Servicing this equipment requires working with the equipment
while AC power is applied. Extreme caution must be
exercised during these procedures.
RESUSCITATION
Personnel working with or near hazardous chemicals or voltages should be
familiar with modern methods of resuscitation.
USE SAFETY-APPROVED EQUIPMENT
When cleaners are being applied, approved explosion-proof lights, blowers,
and other equipment shall be used. Ensure that firefighting equipment is
readily available and in working order. Keep cleaners in special
polyethylene bottles or in safety cans and in minimum quantities. Discard
soiled cloths into safety cans.
3862 Autotrack Controller x
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Chapter 1 - General Information
Chapter 1
General Information
1.1 Introduction
This manual provides general operation and maintenance
instructions for the Series 3860 Digital Controller. This manual
includes optional equipment and features that may not be present
in all configurations.
1.2 Contents of this Manual
This manual consists of the following chapters:
Chapter 1 General Information
Chapter 2 Installation
Chapter 3 Operation
Chapter 4 Principles of Operation
Chapter 5 Maintenance
Chapter 6 Parts List
Chapter 7 Drawings
1.3 Use of this Manual
This manual is divided into chapters, each with a specific purpose. The Table
of Contents lists all chapters and paragraphs with their titles and page
numbers. Illustrations, tables, and diagrams are provided to support the text.
Lists of illustrations and tables indicate their numbers, titles, and page
numbers. Abbreviations, phrases, and words appear in the text exactly as
they appear on the equipment.
3862 Autotrack Controller 1-1
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Chapter 1 - General Information
1.4 Format of this Manual
Paragraph headings of this manual are formatted to indicate subordination of
subject matter as follows:
1.1 Primary Heading
1.1.1 First Subordinate
1.1.1.1 Second Subordinate
1.1.1.1.1 Third Subordinate
1.1.1.1.1.1 Fourth Subordinate
1.5 Change Recommendations
Submit recommendations concerning changes to ViaSat.
1.6 Description
The Series 3860 of Digital Controllers (Figure 1.1) provide antenna pedestal
or positioner control in tracking, communications, and microwave
instrumentation applications. These controllers implement full digital servo loop
control and compensation in several control modes suitable for use with two-axis
pedestals and may be adapted for use with positioners having up to eight axes. The
controllers are available in a variety of physical and functional configurations to
provide maximum flexibility for any given application.
(NOTE: This illustration shows the single-chassis version.)
Figure 1.1. 3860 Digital Controller
3862 Autotrack Controller 1-2
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Chapter 1 - General Information
1.6.1 Major Components
The Digital Controller is made up of several components combined in
modular fashion to provide the desired functions and physical configuration.
Each block or module performs a unique function. For applications not
requiring a particular function, the assembly or module providing that
function may be excluded from the controller. The following are the principal
components of the Digital Controller (see Chapter 4 for detailed descriptions
of each):
• Servo Assembly
• Synchro/Resolver Assembly
• Operator/Remote Interface Assembly
• Autotrack Assembly (Optional)
• Resolver Reference Assembly
• Analog Servo Rate Loop Assembly (Optional)
• Front Panel Assembly
• Motherboard Assembly
• DC Power Supply
1.6.2 Functional Configurations
The Model 3861 Manual Controller provides basic operator control of the
pedestal. This controller is equipped with a Servo Assembly and a
Synchro/Resolver Assembly and includes the enclosures and/or interfaces
appropriate to the physical configuration selected. The Model 3861 operates
using an indoor control panel or an external computer and remote interface.
The Model 3862 Autotrack Controller includes the Autotrack Assembly
which allows operation with automated tracking systems. The automated
tracking (Autotrack) function requires input of both a signal strength and a
tracking video signal from the receiver. The Autotrack function can be used
with a wide variety of feeds and is compatible with ViaSat Satellite Networks
ESCAN and MONOSCAN tracking feeds and the associated digital
demodulation techniques.
The Model 3863 Steptrack Controller is equipped with steptrack capability
which allows operation with step tracking subsystems. The steptrack
function is contained within the Operator/Remote Interface Assembly or
within a computer subsystem equipped with the PC Interface Module. The
steptrack function requires an automatic gain control (AGC) signal from a
receiver and may be used with a wide variety of feeds.
3862 Autotrack Controller 1-3
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Chapter 1 - General Information
1.6.3 Physical Configurations
The unit may be provided with all components housed in either one or two
rack-mounted chassises as shown in Figure 1.2.
A single-chassis configuration is used in most systems. Using the single-
chassis requires that all electrical control cables extend from the pedestal into
the control room and be connected directly to the 3860.
Two-chassis configurations are used in large pedestal systems where it is
possible to mount a rack-mounted chassis within the base extension. The
two-chassis configuration greatly reduces the length and number of
electrical control cables from the pedestal into the control room by placing
the functional modules that interface to the pedestal within the pedestal
equipment. The second chassis provides the operator controls and indicators.
The two chassises are functionally connected by a full-duplex fiber optic link.
The operator interface components include the keypad, display screen,
position knobs, and power switch on the front panel. The unit chassis is 5.25
inches high and can be mounted in a standard, 19-inch-wide equipment rack.
All of the Series 3860 Digital Controller's printed wiring boards provide
direct cabling access through integral connector plates on the unit's rear
panel. A fan in the rear panel provides cooling for the enclosure.
3862 Autotrack Controller 1-4
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Chapter 1 - General Information
Figure 1.2. 3860 Digital Controller Functional Configurations
3862 Autotrack Controller 1-5
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Chapter 1 - General Information
1.7 Specifications
Equipment characteristics and specifications are provided in Tables 1.1 and
1.2.
Table 1.1. Physical and Electrical Specifications
Characteristic Specification
Dimensions
Height 5.25 in. (133.35 mm)
Depth 18.00 in. (457.20 mm)
Width 19.00 in. (482.60 mm)
Weight 20 lb nominal
Input Power Requirements
Voltage 110V ac at 150W or 220V ac at 150W
Frequency 47 to 440 Hz
Host Communication Interface Serial Link
Selectable Media RS-422, RS-232, or IEEE-488
Communication Rate 9600 Baud
Controls and Indicators
Display High contrast LCD display
Mode Selection Menu-driven function keys plus full numeric
keypad
Axis Position Controls Analog position knobs and joystick for 2 axes
Status Displays Up to 32 optically isolated and 32 TTL lines to
report various system functions
Servo Functions Digital servo compensation with four user-
selectable servo loop bandwidths. Typically two
axes can be configured to control up to eight
pedestal or positioner axes
Pedestal Control Modes Standby, Rate (Slew), Position, Autotrack, Slave,
Remote and Scan
Pedestal Position Feedback Six independent synchro/resolver to digital
converters channels
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Chapter 1 - General Information
Table 1.2. Environmental Specifications
Characteristic Specification
Ambient Temperatures
Operation -0°C to +40°C (+32°F to +104°F)
Storage -20°C to +60°C (-4°F to +140°F)
Relative Humidity 0% to 95%, without condensation
Altitude
Operation 10,000 feet
Storage 50,000 feet
Cooling Fan cooling
Shock and Vibration Normal benchtop handling and commercial
shipping
1.8 Glossary of Symbols and Abbreviations
The following list defines symbols and abbreviations used in this manual.
Symbol or
Abbreviation
Definition
ABS automatic beam switching
ac alternating current
ACQTIM acquire time
A/D analog-to-digital
ADC analog-to-digital converter
AGC automatic gain control
AMPL amplitude
AUTOTRK autotrack
AUTODV auto diversity
AZ azimuth
BIT built-in test
BKMODE backup mode
C celsius
CHANN channel
CMD, CMND command
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Chapter 1 - General Information
Symbol or
Abbreviation
Definition
COMPSN compensation
CONFIG configuration
DAC digital-to-analog converter
dc direct current
DISABL disable
EL elevation
F fahrenheit
FDSCAN feed scan
FNTPNL front panel
Hz hertz
I/O input/output
kHz kilohertz
LCD liquid crystal display
LCL local
LED light-emitting diode
LCLRMT local/remote
LNCHAC launch angle
LOWTRK low track
mA milliampere
mm millimeter
MAXANG maximum angle
MINANG minimum angle
MLTPTH multipath
NS PWR noise source power
NVRAM nonvolatile RAM
ORI operator remote interface
PC personal computer
PED pedestal
PID proportional/integral/derivative
POS, POSN position
POSERR position error
POSMEM position memory
POSNFL, PFLT position filter
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Chapter 1 - General Information
Symbol or
Abbreviation
Definition
POSTIM position time
PSTART position start
PWB printed wiring board
PWR power
RAM random-access memory
RATEFL, RFLT rate filter
RCALL recall
RCVR receiver
RF radio frequency
ROM read-only memory
RTEMEM rate memory
RTETIM rate time
RUNSTP run step response
SECT sector
STAT status
STPRSP step response
STEPTR step track
STPSZE step size
TESTPT test point
THRHLD threshold
TIM DUR time duration
TQBIAS, TQB torque bias
TRAVL travel
TTL transistor-transistor logic
V volts
W watts
3862 Autotrack Controller 1-9
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