RESEARCH CONCEPTS RC4500 User manual

RC4500 ANTENNA CONTROLLER

USER’S MANUAL

RESEARCH CONCEPTS INC.

9501 Dice Lane

Lenexa, Kansas 66215 USA

VOICE: (913) 422-0210 FAX: (913) 422-0211

www.researchconcepts.com support@researchconcepts.com

Contents subject to change

Serial No________

REVISION HISTORY

DATE

MODIFICATION

SW VERSION

INITIALS

27 SEP 2014

Initial release

1.09

20 NOV 2014

Initial update

1.09

5 JUN 2015

Update Chapter 2, replace board-stack

information with separate rack-mount and

embedded information

1.09

JDK

17 JUN 2015

Update of Chapter 3 screens.

1.09

18 JUN 2015

Corrected discrepancies in the AZ Jam

Slop and Runaway Slop descriptions

1.09

JDK

18 AUG 2016

Large Updates with software update to

version 2.03.

Removed all references to LOCATE in the

MENU mode, updated chapter 3 to remove

references to LOCATE, Preset Satellites,

Preset Locations and STOW/DEPLOY. Moved

Operation Overview to the Introduction

chapter. Change STORE to SETUP in the

MENU mode. Many corrections to CONFIG

mode screens.

2.03

JDK

05 OCT 2016

Reorganized entire manual. Additional

corrections made to many screenshots and

descriptions based on software version

2.03.

Reorganized chapters, the installation

procedure is now separated from the

trouble-shooting section.

Created hyper-links for chapter and

section references within the document.

2.03

JDK

10 NOV 2016

Updated warranty

N/A

3 JAN 2017

Added detailed descriptions of signals

for J6 – Auxiliary I/O and J7 – Antenna

I/O connectors in sections 3.1.2.3 and

3.1.2.4

2.03

JDK

LIMITED WARRANTY

New Products

Research Concepts, Inc., RCI, warrants to the original purchaser this product shall be free from

defects in material and workmanship for one year, unless expressed otherwise, from the date of

the original purchase. During the warranty period, RCI will provide, free of charge, both parts

and labor necessary to correct such defects.

To obtain such a warranty service, the original purchaser must:

1. Notify RCI as soon as possible after discovery of a possible defect, with:

a. Model and serial number

b. Purchase date

c. Detailed description of the problem and circumstances when problem appears,

including details on the electrical connection to associated equipment

2. Obtain an RMA number from RCI, then ship the product to RCI in original packaging or

its equivalent, fully insured and shipping/customs charges prepaid. RCI is not responsible

for damage during shipping.

Repaired Products

RCI warrants repairs to be free from defects in material and workmanship for six months from

the repair date. If a possible defect is found, use the same process as above to obtain service.

Repair fees for end users are a flat charge based on the equipment being repaired.

Repair fees for Dealers and OEMs are an hourly labor charge plus parts cost. ** Dealers and

OEMs are responsible for receiving and shipping the products from their customer. **

___

RCI will pay for domestic shipping to return the product using the same method that RCI

received it. Customers are responsible for all international shipping charges.

Correct maintenance, repair, and use are important to obtain proper performance from this

product. Therefore, read the instruction manual carefully and completely. This warranty does

not apply to any defect that RCI determines is due to, but not limited to:

1. Improper maintenance or repair, including the installation of parts or accessories

that do not conform to the quality and specifications of the original parts

2. Misuse, abuse, neglect, or improper installation including disregard for

installation of backup or safety override equipment

3. Accidental or intentional damage, including lightning

4. Water / Liquid damage

There are no implied warranties.

The foregoing constitutes RCI’s entire obligation with respect to this product, and the original

purchaser and any user or owner shall have no other remedy and no claim for incidental or

consequential damages.

For service:

(913)422-0210 support @researchconcepts.com

TABLE OF CONTENTS

1.0 INTRODUCTION.................................................................................................................................................1

1.1 MANUAL ORGANIZATION .....................................................................................................................................1

1.2 RC4500 FEATURES ..............................................................................................................................................3

1.3 HARDWARE OVERVIEW........................................................................................................................................4

1.4 SOFTWARE INITIALIZATION...................................................................................................................................5

1.5 SPECIFICATIONS....................................................................................................................................................8

2.0 BASIC OPERATION............................................................................................................................................9

2.1 USER INTERFACE..................................................................................................................................................9

2.1.1 Keypad Usage ............................................................................................................................................10

2.1.2 Data Entry..................................................................................................................................................13

2.1.3 Display Layout ...........................................................................................................................................15

2.1.4 Menu Structure...........................................................................................................................................16

2.2 OPERATING MODE..............................................................................................................................................18

2.2.1 MANUAL Mode Basics...............................................................................................................................18

2.2.2 MENU Mode Basics...................................................................................................................................19

2.3 PROGRAMMING MODE........................................................................................................................................20

2.3.1 CONFIG Mode Basics................................................................................................................................20

2.3.2 MAINTENANCE Mode Basics ...................................................................................................................20

3.0 MECHANICAL & ELECTRICAL INSTALLATION....................................................................................21

3.1 RACK MOUNT ENCLOSURE TO AIU....................................................................................................................22

3.1.1 Mechanical Mounting ................................................................................................................................22

3.1.2 Electrical Interface.....................................................................................................................................23

3.1.2.1 Power Entry...........................................................................................................................................................24

3.1.2.2 Resolver Inputs......................................................................................................................................................24

3.1.2.3 Auxiliary I/O..........................................................................................................................................................25

3.1.2.4 Antenna I/O ...........................................................................................................................................................28

3.1.2.5 Sensors...................................................................................................................................................................33

3.1.2.6 AGC....................................................................................................................................................................... 34

3.1.2.7 RF Input................................................................................................................................................................. 35

3.1.2.8 Integrated IP Option ..............................................................................................................................................35

3.1.2.9 Spare Connectors...................................................................................................................................................36

3.1.2.10 Serial Remote Control .........................................................................................................................................36

3.2 RACK MOUNT ENCLOSURE W/DIRECT DRIVE TO DC MOTORS..........................................................................37

3.2.1 Mechanical Mounting ................................................................................................................................37

3.3.2 Electrical Interface.....................................................................................................................................38

3.3 EMBEDDED CONTROLLER TO AIU......................................................................................................................39

3.3.1 Mechanical Mounting ................................................................................................................................39

3.3.2 Electrical Interface.....................................................................................................................................40

3.3.2.1 DC Power Input.....................................................................................................................................................41

3.3.2.2 Resolver Inputs......................................................................................................................................................42

3.3.2.3 I/O and Limits........................................................................................................................................................43

3.3.2.4 RF..........................................................................................................................................................................44

3.3.2.5 Integrated IP Option ..............................................................................................................................................44

3.4 BOARD-STACK IN OUTDOOR ENCLOSURE W/DIRECT DRIVE TO DC MOTORS ....................................................45

3.4.1 Mechanical Mounting ................................................................................................................................45

3.4.2 Electrical Interface.....................................................................................................................................46

3.4.2.1 AC Power Input.....................................................................................................................................................48

3.4.2.2 Motor Drive...........................................................................................................................................................49

3.4.2.3 Computing and Interface Board.............................................................................................................................50

3.4.2.3.1 Receiver 1.......................................................................................................................................................51

3.4.2.3.2 Polarization Sensors.......................................................................................................................................52

3.4.2.3.3 Azimuth Limits...............................................................................................................................................53

3.4.2.3.4 Elevation Limits.............................................................................................................................................54

3.4.2.4 Resolver Board ......................................................................................................................................................55

3.4.2.4.1 Pol Resolver...................................................................................................................................................56

3.4.2.4.2 El Resolver..................................................................................................................................................... 57

3.4.2.4.3 Az Resolver.................................................................................................................................................... 58

4.0 SOFTWARE CONFIGURATION / INSTALLATION................................................................................... 59

4.1 SOFTWARE INITIALIZATION ................................................................................................................................ 60

4.1.1 Mount LAT/LON Definition ....................................................................................................................... 60

4.1.2 Define Antenna Size................................................................................................................................... 61

4.1.3 Define Polarization Equipment.................................................................................................................. 61

4.1.4 Define System Time.................................................................................................................................... 62

4.2 INITIAL CALIBRATION......................................................................................................................................... 63

4.2.1 Position Sense Direction............................................................................................................................ 63

4.2.2 Fast and Slow Speed Settings .................................................................................................................... 64

4.2.3 Determine Offset Angles & Reference Voltages......................................................................................... 65

4.2.3.1 Elevation Offset Angle.......................................................................................................................................... 65

4.2.3.2 Azimuth Offset Angle............................................................................................................................................ 66

4.2.3.2.1 Azimuth Offset Angle – Northern Hemisphere.............................................................................................. 66

4.2.3.2.2 Azimuth Offset Angle – Southern Hemisphere.............................................................................................. 67

4.2.3.3 Polarization Reference Voltage and Offset Angle................................................................................................. 68

4.2.3.3.1 Polarization Reference Voltage for Potentiometer......................................................................................... 69

4.2.3.3.2 Polarization Offset for Resolver..................................................................................................................... 70

4.2.4 Scale Factors ............................................................................................................................................. 71

4.2.4.1 Elevation Scale Factor........................................................................................................................................... 71

4.2.4.2 Azimuth Scale Factor............................................................................................................................................ 71

4.2.4.3 Polarization Scale Factor....................................................................................................................................... 72

4.2.4.3.1 Polarization Scale Factor for Potentiometer................................................................................................... 72

4.2.4.3.2 Polarization Scale Factor for Resolver........................................................................................................... 72

4.2.5 Verify and Set Limits.................................................................................................................................. 73

4.3 FINAL CALIBRATION........................................................................................................................................... 75

4.3.1 Drive System Checkout .............................................................................................................................. 75

4.3.2 Signal Strength Adjustment........................................................................................................................ 76

4.3.2.1 Signal Strength Channel........................................................................................................................................ 76

4.3.2.2 Signal Strength Channel Configuration................................................................................................................. 76

4.3.2.3 Amplifier Gain vs. Frequency Characterization .................................................................................................... 76

4.3.3 Operational Presets................................................................................................................................... 77

4.3.4 Miscellaneous Adjustments........................................................................................................................ 77

5.0 MODES – IN DEPTH DESCRIPTIONS.......................................................................................................... 79

5.1 OPERATING GROUP............................................................................................................................................ 79

5.1.1 Manual Mode............................................................................................................................................. 79

5.1.2 Menu Mode ................................................................................................................................................ 81

5.1.2.1 Setup...................................................................................................................................................................... 82

5.1.2.2 Recall..................................................................................................................................................................... 83

5.1.2.3 Delete .................................................................................................................................................................... 83

5.1.2.4 MoveTo................................................................................................................................................................. 84

5.1.2.5 Track ..................................................................................................................................................................... 85

5.2 PROGRAMMING GROUP...................................................................................................................................... 86

5.2.1 Configuration Mode................................................................................................................................... 86

5.2.1.1 NORMAL ACCESS ITEMS................................................................................................................................. 88

5.2.1.1.1 Expert Access Level....................................................................................................................................... 88

5.2.1.1.2 TLE 1 Data..................................................................................................................................................... 89

5.2.1.1.3 TLE 2 Data..................................................................................................................................................... 90

5.2.1.2 INSTALLATION ACCESS ITEMS ..................................................................................................................... 91

5.2.1.2.1 Elevation Calibration..................................................................................................................................... 91

5.2.1.2.2 Azimuth Calibration....................................................................................................................................... 92

5.2.1.2.3 Polarization Calibration................................................................................................................................. 93

5.2.1.2.4 Feed Definition .............................................................................................................................................. 94

5.2.1.2.5 External Sig Factors....................................................................................................................................... 95

5.2.1.2.6 Location Reset ............................................................................................................................................... 96

5.2.1.3 Super-User Access Items....................................................................................................................................... 97

5.2.1.3.1 System Definition .......................................................................................................................................... 97

5.2.1.3.2 Azimuth Angle Movement............................................................................................................................. 98

5.2.1.3.3 Azimuth Count Movement............................................................................................................................. 99

5.2.1.3.4 Azimuth Drive Parameters........................................................................................................................... 100

5.2.1.3.5 Elevation Angle Movement ......................................................................................................................... 102

5.2.1.3.6 Elevation Count Movement..........................................................................................................................103

5.2.1.3.7 Elevation Drive Parameters..........................................................................................................................104

5.2.1.3.8 Polarization Angle Movement......................................................................................................................106

5.2.1.3.9 Polarization Drive Parameters......................................................................................................................107

5.2.1.3.10 Track Factors..............................................................................................................................................109

5.2.1.3.11 Shake..........................................................................................................................................................112

5.2.1.3.12 Reset Defaults.............................................................................................................................................113

5.2.2 Maintenance Items ...................................................................................................................................114

5.2.2.1 Analog to Digital Voltage....................................................................................................................................115

5.2.2.1.1 10 Bit ADC Voltages ...................................................................................................................................115

5.2.2.1.2 12 Bit ADC Voltages ...................................................................................................................................116

5.2.2.2 Drive Error Resets ...............................................................................................................................................117

5.2.2.3 Time Maintenance ...............................................................................................................................................118

5.2.2.4 GPS Communications (Optional) ........................................................................................................................119

5.2.2.5 Limits Maintenance .............................................................................................................................................120

5.2.2.6 Shake ...................................................................................................................................................................121

5.2.2.7 System Information..............................................................................................................................................122

5.2.2.7 Resolver Offset Calculator...................................................................................................................................123

6.0 SUPPORT..........................................................................................................................................................125

6.1 TROUBLESHOOTING..........................................................................................................................................125

6.1.1 Limit Switches...........................................................................................................................................125

6.1.2 Motor Drive..............................................................................................................................................127

6.1.3 Automatic Movements ..............................................................................................................................127

6.1.4 GPS ..........................................................................................................................................................127

6.1.5 Alarm Displays.........................................................................................................................................128

6.1.5.1 FLASH / NVRAM VERSION MISMATCH ......................................................................................................128

6.1.5.2 FLASH / NVRAM DATA CORRUPT................................................................................................................128

6.1.5.3 LOW BATTERY ALARM..................................................................................................................................128

6.1.5.4 TIME / DATE ERROR........................................................................................................................................128

6.1.5.5 AZIMUTH / ELEVATION / POLARIZATION JAMMED................................................................................128

6.1.5.6 AZIMUTH / ELEVATION / POLARIZATION RUNAWAY............................................................................128

6.1.5.7 LIMITS INACTIVE WARNING ........................................................................................................................129

6.1.5.8 AZIMUTH DRIVE FAULT................................................................................................................................129

6.1.5.9 ELEVATION DRIVE FAULT............................................................................................................................129

6.1.5.10 EMERGENCY STOP........................................................................................................................................129

6.1.5.11 MAINTENANCE ALARM...............................................................................................................................129

6.1.5.12 MOVEMENT INTERLOCK.............................................................................................................................129

6.2 ACU TOPICS ....................................................................................................................................................130

6.2.1 Antenna Pointing Solution .......................................................................................................................130

6.2.2 Timekeeping .............................................................................................................................................131

6.2.3 Drive System.............................................................................................................................................131

6.2.4 Polarization Control.................................................................................................................................132

APPENDIX A – EXPERT ACCESS CODES

APPENDIX B – MOUNT SPECIFIC DATA

APPENDIX C – ENCLOSURE SPECIFIC DATA

The following appendices describe optional features of the RC4500. These appendices will be

included in the manual if the option is present.

APPENDIX REM : SERIAL-BASED REMOTE CONTROL

APPENDIX IP : IP-BASED REMOTE CONTROL

APPENDIX TRK : INCLINED ORBIT TRACKING

APPENDIX TLE : TWO LINE ELEMENT TRACKING

APPENDIX DVB : INTEGRATED DVB RECEIVER

APPENDIX BCN : INTEGRATED BEACON RECEIVER

RC4500 Antenna Controller Chapter 1 Introduction

1.0 INTRODUCTION

The RC4500 Antenna Control Unit (ACU) boardset consists of stackable set of cards allowing for compact

and flexible ACU packaging. The design and function of the RC4500 is derived from Research Concepts

Incorporated's mobile ACU, the RC4000.

PLEASE READ AND UNDERSTAND THE MANUAL. Due to the complexity of the functions performed

by the RC4500, time invested in understanding its installation and operation will be well spent.

1.1 Manual Organization

The RC4500 boardset allows for ACU functionality to be packaged in various configurations. Many

hardware and software options are available for use with the RC4500 architecture. This manual is

organized to:

1) describe common hardware and software elements that will apply to all instances of the RC4500 and

2) provide a structure to allow definition of elements unique to a specific use of the RC4500.

Chapter 1 summarizes the contents of the manual and highlights the functionality and features of the

RC4500.

Chapter 2 describes the RC4500 user interface and basic operations.

Chapter 3 describes the RC4500 boardset hardware, interfaces and common external components,

covering the mechanical and electrical hardware installation.

Chapter 4 covers the RC4500 calibration and installation procedures related to the software and user

interface.

Chapter 5 provides an in-depth description of all modes and configuration screens in the RC4500.

Chapter 6 describes trouble-shooting information, error code descriptions and other ACU topics.

Appendix A supplies the expert access codes on a single page, which at management’s discretion, may

be removed to eliminate the possibility of inexperienced users inadvertently corrupting configuration data.

Appendix B, titled "MOUNT SPECIFIC DATA", details functions and values unique to a specific antenna

mount.

Appendix C, titled "ENCLOSURE SPECIFIC DATA", details mechanical and electrical details on how the

RC4500 is packaged. This appendix may not be supplied from RCI if the boardset is not packaged in an

RCI provided enclosure.

Separate appendices describe optional features of the RC4500. Example optional appendices that could

accompany the manual include:

APPENDIX REM - SERIAL-BASED REMOTE CONTROL

APPENDIX IP - IP-BASED REMOTE CONTROL

APPENDIX TRK - INCLINED ORBIT TRACKING

APPENDIX TLE - TWO LINE ELEMENT TRACKING

APPENDIX DVB - INTEGRATED DVB RECEIVER

APPENDIX BCN - INTEGRATED BEACON RECEIVER

RC4500 Antenna Controller Chapter 1 Introduction

MANUAL CONVENTIONS

Throughout the manual, representations of screens the user will see will be shown in the boxed format

that follows:

AZ: 179.97 RF: 50 MANUAL

EL: 42.45 SAT:

PL: 30.01 V SPD:FAST UTC

<MODE>MENU <0-9>JOG ANTENNA 14:25:47

The following table shows typical abbreviations used both on RC4500 screens and in the manual’s text.

ITEM

ABREVIATION(S)

Azimuth

AZIM, Azim

Elevation

ELEV, Elev

Polarization

POL, Pol

Clockwise

Counter-Clockwise (Anti-Clockwise)

CCW

Down

Latitude

LAT

Longitude

LON

Satellite

SAT

Global Positioning System

GPS

Liquid Crystal Display

LCD

Automatic Gain Control

AGC

Satellite longitudes are presented in degree/decimal degree (79.000 W) format since that is the standard

representation of satellite positions. Latitude and longitude of the mount are presented in

degree/minute/second (38°56’23 N) format.

When referring to a particular RC4500 mode of operation, that mode’s name will be capitalized – ex.

MENU.

Throughout the RC4500 manual and software, the latitude, longitude and true heading of the mount are

collectively referred to as the mount’s “position”.

Movements of the mount (as seen from behind the antenna, looking at the arc of satellites) are

represented by graphing the azimuth and elevation axes as shown below.

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