Sea Tel 4012 User manual

Field Service Procedure – Replacement Pol Motor Kit, 4012

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Document No

136830 Rev A

Tel, Inc. This document may not be reproduced or distributed in any form without prior written

consent of Sea Tel, Inc. 



1. BriefSummary:

Troubleshootingdocumentfordiagnosingafaultwithandreplacingthepolmotoronthe4012antenna.

2. Checklist:

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VerifyRangeofMotion

VerifyPotRange

MeasureMotorVoltage

VerifyHarness

3. TheoryofOperation:

ToensuretheLNBiscorrectlyalignedtothelinearpolarizedreceivesignaltheantennasfeedassemblycanbedriven

througha270degreerangeofmotionbya24VDCmotor.BasedonthevesselsGPSpositionandthelookangletothe

desiredsatellitethesystemwillcalculatethenumericalvalueforthepositionofthepolassembly.TheICUwillthensend

thevoltagetodrivethepolmotoruntilthepolpotoutputsthecorrectvalue,atwhichpointthefeedwillbealignedto

theincomingsatellitesignal(providedthepothasbeencalibratedcorrectly).ThenasthevesselsailsandtheGPS

positionchangesthelookangletothesatellitewillalsochangeandadjustmentswillbemadetomaintaingoodcrosspol

isolation(alignmenttothesatelliteslinearsignal).

Oneindicationthatthereisafaultwiththefeedalignmentofthesystemisthatthetargetlightwillbepermanently

illuminatedontheMXPandtheantennawon’ttargetcorrectly.Ifthisisthecaseitwillsit8degreesaboveor8degrees

belowoftheelevationlookangle.Thisisbecausepartoftheantennastargetingprocedureistotargetthesystemabove

orbelowthesatellite,tocalculatetheautothresholdsettingbasedonthenoisefloorlevel,thenitwillalignthefeedfor

thecorrectreceptionpositionbasedonthevesselsGPSpositionbeforetargetingthesatellite.

Ifthesystemisunabletodrivethepolmotororthepolpothasfailed,thecorrectfeedbacksignalisnotobtained,the

systemcan’tcompletethetargetingprocessandtheantennawillstayinthisposition.Settingthepoltypemanualmode

willallowtheantennatotargetcorrectly,misalignmentofthefeedwillcausebadcrosspolisolation.

4. VerifytheFeedAssembliesRangeofMotion:

Toverifyifthe4012antennaspolarityfunctioniscalibratedcorrectlyrefertosection3ofthisdocument.

Onceverifiedthatthepotiscalibratedthenextstepwillbetoverifythatthesystemhasthefullrangeofmotion(135

degreesofphysicalrotation),verifyingthatthepolpotisoutputtingthecorrectresistancethroughitsrangeandalso

thatthepolmotorisdrivingtheassemblycorrectly.

1. Toverifytherangeofmotiononthefeedassemblyenterintothe“Reflector”screenundertheconfiguration

optionsandsetthepolangdrivemodetomanualandclickthesavebutton.

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Field Service Procedure – Replacement Pol Motor Kit, 4012

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Thiswillnowgiveyoutheabilitytomanuallydrivethepolasopposedtothefeedautomaticallyaligningitself

basedonthevesselsGPSlocationandthelookangletothedesiredsatellite.

2. Nowenterintothe“PositionAntenna”screenfromthetoolsmenuandenterthevalue“‐90.0”intothelinear

windowofthepolangtargetoptionandpresstheenterkeyonthekeyboard.

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Thefeedhornshouldrotate45.0degreesclockwise(whenviewedfromthefrontofthereflector)sothatthe

alignmentmarksofthephasecardinthefeedhornarealignedvertically,fromlefttoright(asshownabove).

3. Nowenterintothevalue“00.0”intothelinearwindowofthepolangtargetoptionandpresstheenterkeyon

thekeyboard.

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Thefeedhornshouldrotate45.0degreescounter‐clockwise(whenviewedfromthefrontofthereflector)so

thatthealignmentmarksofthephasecardinthefeedhornarealigneddiagonallyinanorth/eastposition(as

shownabove).

4. Nowenterintothevalue“90.0”intothelinearwindowofthepolangtargetoptionandpresstheenterkeyon

thekeyboard.

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Thefeedhornshouldrotate45.0degreesclockwise(whenviewedfromthefrontofthereflector)sothatthe

alignmentmarksofthephasecardinthefeedhornarealignedhorizontally,fromtoptobottom(asshown

above).

Field Service Procedure – Replacement Pol Motor Kit, 4012

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Document No

136830 Rev A

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5. Nowenterintothevalue“180.0”intothelinearwindowofthepolangtargetoptionandpresstheenterkeyon

thekeyboard.

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Thefeedhornshouldrotate90.0degreesclockwise(whenviewedfromthefrontofthereflector)sothatthe

alignmentmarksofthephasecardinthefeedhornarealigneddiagonally,inanorth/westposition(asshown

above).

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6. Ifthesystemcompletesalloftheaboveteststhanthepolangassemblyisoperatingcorrectly.

Settheantennabackintoautomaticpolangmodebyenteringintothe“Reflector”screenunderthe

configurationoptionsandsetthepolangdrivemodeto“Automatic”andclickthesavebutton.

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TheantennawillnowautomaticallycalculatethecorrectreceptionpositionforthefeedbasedonthevesselsGPS

locationandthelookangletothedesiredsatellite.

Shouldthefeedassemblydrive,butnottargetthecorrectpositionthisisanindicationthatthepolpotisnotcalculating

thefeedbackcorrectlyanditsresistanceshouldbeverifiedaspertheverifyresistanceofthepotsectionofthis

document.

Nodriveatallindicatesafailurewiththe24DCpolangmotorasperthemeasuremotorvoltagesectionofthis

document. 

Field Service Procedure – Replacement Pol Motor Kit, 4012

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Document No

136830 Rev A

Tel, Inc. This document may not be reproduced or distributed in any form without prior written

consent of Sea Tel, Inc. 

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5. MeasureMotorVoltage:

Leavingthepolangsettinginmanualmodeapplydrivetothefeedassemblyandmeasurethevoltagetothemotoron

theIDCconnector,24VDCshouldbepresent.Ifvoltageispresentbutthemotorisn’tdrivingthemotorisdefectiveand

needsreplacing.Ifnovoltageispresentverifytheconnectionsofthereflectorharnessbymeasuringpintopinasperthe

belowdiagram.

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Iftheharnessconnectionsaregood,thentheICUmainPCBisn’toutputtingthevoltagetodrivethemotorandneeds

replacing.AslongasthepolrangeiswithinthepotlimitstheICUwillissuethevoltagetodrivethemotorbasedonthe

antennatargeting,achangeinthevesselsGPSpositionoroperatorinputs.Themotorwillthendrivethefeeduntilthe

correctoutputfromthepothasbeenreceived,atwhichpointthefeedwillbeinthecorrectreceptionposition(providing

thesystemisfunctioningandcalibratedcorrectly).Thereforethereisalsothepossibilityforapoldrivefaulttobecaused

bytheICUmainPCB. 

Field Service Procedure – Replacement Pol Motor Kit, 4012

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Document No

136830 Rev A

Tel, Inc. This document may not be reproduced or distributed in any form without prior written

consent of Sea Tel, Inc. 

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6. Replacingthe4012PolMotorAssembly:

6.1. Tools.

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2.5mmAllenWrench/Key

4mmAllenwrench/Key

Snips/Cutters

17mmWrench/Spanner

3mmAllenWrench/Key

2mmFlatBlade(Terminal)Screwdriver

CableTies/TieWraps

Loctite242

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6.2. Procedure.

Procedureforreplacingthepolmotor,SeaTelkitpartnumber:136742(polpotpartnumber:134870‐3).

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*Caution:Powerdownthepedestalbeforefollowingthis

procedure.

1.Usinga2.5mmAllenwrenchremovethefourscrews

securingthefeedhorntothefrontofthereflectorand

removethefeedhorn.Savethehardwareforfuturesuse.

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2.Disconnectthemilitaryspecconnectorfromitssocketto

allowaccesstothescrewstoremovetheupperbracket.

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3.Removethe5screwswhichsecuringthemountingplate

withthecannonconnectionandIDCconnectionPCBtothe

RFcage.Retainthehardwareforfutureuse.

*Note:Themountingplatewillremainattachedtothe

harnesswhiletheRFcageisremovedfromtherearofthe

reflector.

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Field Service Procedure – Replacement Pol Motor Kit, 4012

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4.SnipthecabletiesecuringtheRFcageharnesstothe

mountingplate.

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5.Disconnectthepolpot,polmotorandopticalswitchIDC

connectionsfromtheterminationblock.

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6.DisconnecttheorangecoaxcablefromtheX‐PolLNB.

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7.DisconnecttheyellowcoaxcablefromtheCo‐PolLNB,

mountedontheundersideoftheRFcage.

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8.Snipthecabletiesecuringthereceivecoaxcablestothe

RFcage.

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Field Service Procedure – Replacement Pol Motor Kit, 4012

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9.DisconnecttheDCpowerconnectionfromtheBUC(also

mountedontheundersideoftheRFcage).

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10.DisconnecttheTXIFcoaxcablefromtheBUC.

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11.UnwindtheharnessfromaroundtheRFcageandsetit

overthecrosslevelbeamtoallowremovaloftheRFcage

fromtherearofthereflector.

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12.Usinga17mmwrenchremovethefourmountingnuts

andwasherssecuringtheRFcagefromthebackofthe

reflector.Savethehardwareforfutureuse.

13.SupporttheweightoftheRFcagewhileremovingitfrom

therearofthereflector.

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14.Removethecablewraptofreethepolmotorharnessso

theassemblycanberemoved

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Field Service Procedure – Replacement Pol Motor Kit, 4012

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Document No

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15.Usea3mmAllenwrenchtoremovethe2screwsthat

mountthepolaritymotorbrackettotheRFcagebottom

plate.Retainthishardwareforfutureuse.

16.Pullthedefectivemotorforewardandtiptheittowards

youtoremovethepolaritymotorassembly.

17.Installthereplacementmotorinthesamemannerand

applyingLoctite242tothethreads.Donottightenthe

screwsatthistime.

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18.FliptheRFcageovertoexposethefeed/motor/pot

gears.

19.Useasmallflatbladescrewdrivertoholdthebottomhalf

ofthebacklashgearsteadywhilerotatingthetophalfCW

onetooth(againstthespringaction)andpushthemotor

assemeblyforwardtomateintothedrivengearinthefeed.

20.Onceengagedtightenthescrewssecuringthepolmotor

tothebottomplateoftheRFcage.

*Note:Calibrationofthepolpotisnotrequiredwhen

replacingthemotor. 



21.LocatetheRFcageontotherearofthereflector.

*Note:WhenreinstallingtheRFcageensurethatitis

orientedcorrectlysothatthealignmentpinontheleftside

ofthereflectorwilllocateintotheholeonthebackoftheRF

cage.(InthisorientationtheX‐PolLNBwillbeontherightof

theRFcage).



22.Usingthehardwareremovedinstep12securetheRF

cagetotherearofthereflectorusinga17mmwrench.Apply

Loctite242tothethreads.



Field Service Procedure – Replacement Pol Motor Kit, 4012



Page9of10



Document No

136830 Rev A

Tel, Inc. This document may not be reproduced or distributed in any form without prior written

consent of Sea Tel, Inc. 



23.RoutetheharnessassemblybackovertheRFcageand

connectthefollowingconnections:

24.ConnecttheorangecoaxcabletotheX‐PolLNB(onthe

rightoftheBUC).

25.ConnecttheyellowcoaxcabletotheCo‐PolLNB

(underneaththeBUC).

26.Connecttheblack,TXIFcabletotheBUC.



27.SecurethecoaxcablestotheundersideoftheRFcage

usingcableties.



28.RoutetheBUCDCpowercablearoundbetweenX‐Pol

LNBandtheRFcageandconnectittotheBUC.



29.SittheupperbracketontopoftheRFcageand

reconnecttheIDCconnectorswiththe4‐pinsensor

connectorontheleft,the5‐pinpotconnectorinthecenter

andthe2‐pinmotorconnectorontheright(asshowninthe

imageontheright).



30.Securethepot,motorandsensorharnesstothe

undersideoftheupperbracketusingacabletie.



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