Sea Tel 4012 User manual

Field Service Procedure – Replacement Pol Pot Kit, 4012

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Document No

136829 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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1. BriefSummary:

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

2. Checklist:

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VerifyRangeofMotion

VerifyPotFeedback

MeasureResistance

3. TheoryofOperation:

Apolangpotentiometerisusedtoprovideafeedbackreferenceforthepositionofthefeedassemblyforlinear

polarization.Thepotactsasapotentialdividergivinganoutputvoltagewhichvariesfrom0VDCto5VDCthroughoutthe

feedassembly’s270degreerangeofmotion.The4012antennahasaphasecardinstalledinthefeedhornwhichwill

reflectthesignalmeaningforeach0.5degreeofphysicalrotationofthefeedthechangeinsignalwillbe1.0degree

meaningthatthefeedassemblyofthe4012antennaonlyhastophysicallydrive135degreestoviewthefull270degrees

ofrotation.

TheICUconvertsthevoltageoutputfromthepotintothenumericalvaluetoalignthefeedintherequiredposition

basedonthevesselsGPSlocationandthelookangletotherequiredsatellite.Afailurewiththepotwillcauseittooutput

anincorrectvoltagewillresultinthefeedassemblynotbeingalignedcorrectlycausingbadcrosspolisolation.

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thattheantennawon’ttargetcorrectly.Itwillsit8degreesabove(or8degreesbelowat

highelevationlookangles)thesatelliteselevationlookangle.Aspartoftheantennastargetingprocedurethesystem

willtarget8degreesabove(or8degreesbelowathighelevationlookangles)thesatellite,calculatetheautothreshold

settingbasedonthenoisefloorlevelandthenalignthefeedforthecorrectreceptionpositionbasedonthevesselsGPS

locationandthelookuptable.Ifthesystemisunabletodrivethepolmotortoobtainthecorrectfeedback,orifthepot

hasfailedandwon’tgivethecorrectfeedback,theantennacan’tcompletethetargetprocessandtheantennawillstay

inthisposition.Settingthepolsettingtomanualwillmaketheantennatargetbyremovingtheautomaticfunctionfrom

thetargetingprocess;howeverthemissalignmentofthefeedwillcausebadcrosspolisolation.

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Field Service Procedure – Replacement Pol Pot Kit, 4012

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Document No

136829 Rev A

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4. VerifythePolPotsCalibration:

Toverifyifthe4012antennaspolarityfunctioniscalibratedandoperatingcorrectlydrivethepoltoverifythatthefeedis

alignedcorrectly(thepolpotiscorrectlycalibrated)andalsothatthepotisoutputtingthecorrectresistances

throughoutitsrange.Thiswillalsoverifyifthepolmotorisdrivingcorrectly.

LogintotheMXPandfromtheconfigurationmenuselectthe“Reflector”pagefromtheconfigurationsectionandverify

thepolangdriveoptionissetto“Automatic”.

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Nowselectthe“PositionAntenna”screenfromthetoolswindowandconfigurethesatellitesettingsasfollows:

Longitude=EnterthelongitudinalvalueofyourcurrentGPSlocation.I.e.ifyourcurrentlocationis1degree

westofGMTenter“1.0W”intothelongitudeofthesatelliteparameters.

TXPolarity=HORZ

Nowpressthesubmitbutton(asshownbelow).

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Theantennawillnowtargetthedesiredpositionandalignthefeedaccordingly.Oncetheantennahasstopped

targeting,turnoffthetrackingfunctiontopreventitfromgoingintoasearch.

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Field Service Procedure – Replacement Pol Pot Kit, 4012

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Document No

136829 Rev A

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Viewthefeedhornandverifythatthealignmentpinsofthephasecardarealignedvertically(onthetopandbottomof

thefeedhorn)youshouldalsonoticethetammountingscrewsareparallelwitheachotherasshownbelow…

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Anyerrorinalignmentisanindicationthatthepolpotisnotcorrectlycalibrated.Howeverasmallamountoferrorcould

becalibratedoutbyusingthelinearoffsetsetting(toelectronicallyadjustthepolpostion).

Ifit’sdeemedthereisalargeamountoferrorthencalibratingthepolpotwillberequiredasperFig.22toFig.27in

section8ofthisdocument.

Ifnodrivewasissuedthefunctionofthe24VDCpolangmotorshouldbeverifiedaspersection7ofthisdocument.

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5. 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.

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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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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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Field Service Procedure – Replacement Pol Pot Kit, 4012

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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.



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).

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Field Service Procedure – Replacement Pol Pot Kit, 4012

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136829 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).

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section6ofthisdocument.

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Field Service Procedure – Replacement Pol Pot Kit, 4012

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Document No

136829 Rev A

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6. VerifytheResistanceofthePolPot:

Thepolangpotentiometer(polpot)consistsofaninternalslideraswellasaclockwiseandcounter‐clockwisecontact.To

verifytheresistanceofthepotamultimetercanbeusedtomeasurebetweenthesliderandoneofthewiperswhilst

rotatingtheshaftthroughitsrangeandverifyingthe0–5ohmsisoutputtedcorrectly.RemovethepotfromtheRFcage

asperthereplacementprocedureofthisdocumentandmeasuretheresistance.

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Lookingdownontotheshaftofthepotrotateitclockwiseuntilit

reachesitsendstop.

NowmeasuretheresistancebetweenthesliderandtheCCW

contact(greycable,pin2ontheIDCconnectorandtheredcable

pin3ontheIDCconnector).

Thefeedbackshouldbeapproximately5kohms.

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Nowslowlyrotatetheshaftofthepotcounterclockwise,the

readingshouldcountdownsequentially.Afteroneandahalfturns

thepotwillbeinthecenterofitsrangegivingaresistanceof

approximately2.5kohms.

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Continuetorotatethepotuntilthecounterclockwiseendstop(it

willnowhaveturnedthroughall3rotationsofitsrange),the

resistanceshouldbeapproximately0ohms.

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Leavingthepotatitscounterclockwiseendstopmeasurebetweentheclockwisecontactandtheslider(greycable,pin2

ontheIDCconnectorandthebrowncablepin1ontheIDCconnector)theresistanceshouldbereversedfromthe

previousrotation,reading5ohms.Rotatingtheshaftofthepotclockwiseshouldreducetheresistancethroughitsrange

to0ohms.Anyerrorwiththepotnotgivingthecorrectresistanceisanindicationthepotisdefectiveandneeds

replacing.

Field Service Procedure – Replacement Pol Pot Kit, 4012

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Document No

136829 Rev A

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

consent of Sea Tel, Inc. 



7. 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motherboardPCB.



Field Service Procedure – Replacement Pol Pot Kit, 4012



Page8of16



Document No

136829 Rev A

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

consent of Sea Tel, Inc. 



8. Replacingthe4012PolPotAssembly:

8.1. Tools.



2.5mmAllenWrench/Key

4mmAllenwrench/Key

Snips/Cutters

17mmWrench/Spanner

3mmAllenWrench/Key

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

Ruler/StraightEdge

CableTies/TieWraps

Loctite242



8.2. Procedure.

Procedureforreplacingthepolpot,SeaTelkitpartnumber:136741(polpotpartnumber:115425‐6).



*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.



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

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



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.



Field Service Procedure – Replacement Pol Pot Kit, 4012



Page9of16



Document No

136829 Rev A

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

consent of Sea Tel, Inc. 



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

mountingplate



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

connectionsfromtheterminationblockonthe



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



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

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



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

RFcage.



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