Sea Tel 4012 User manual

Field Service Procedure – Replacement ICU PCB Kit, 4012



Page1of12



Document No

136831 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ICUmainPCBonthe4012antenna.

2. Checklist:



VerifyInitialization

ICUStatusLED

PedestalError

VerifyStabilization/SensorFeedback

Communications(EoC)

PolDrive

3. TheoryofOperation:

TheICUPCBisnowasingleintegratedcomponentwhichcontainsthemainPCB,trackingreceiver,coaxswitchand

abovedeckcommunicationscapability.ADE/BDEcommunicationsarehandlednowbyEthernetoverCoax(EoC)with

diagnosticLEDstoverifythefunction.

Stabilization,targetinganddrivecommandsarecalculatedbytheICUbasedonfeedbackfromthesensorsonthe

motionplatformPCB,headingchangesfromthevesselsgyrocompass,targetcommandsbasedonthevesselsGPS

locationanddesiredsatelliteaswellasinputsfromtheoperatorandtrackingdecisionsbasedonthehighestsignal

strength.

AfterdrivecommandshavebeenissuedorfeedbackfromthesensorsonthemotionplatformPCBhavebeencalculated

basedonvoltagechangeovertimetocalculatetheforcesexertedonthesystemtheICUPCBwillsendthecommandto

themotordriverenclosure(MDE)whichinturnwilldrivethebrush‐lessDCmotor(BLDC)todrivetherelevantaxisan

equalandoppositeamounttotheforcebeingexertedonthesystem.

L‐BandIFsignalsarefedintothetrackingreceiverwhichisnowintegratedintotheICU(asopposedtobeinginstalledin

thebelowdecks)shorteningthedistanceofthereceivepathandofferinghighersignalstrengththanpreviousdesigns.

ThreecoaxcoaxialconnectionsarealsointegratedontothePCBforthereceiveoutputtotherotaryjointandbelow

decks(alongwiththeEoC)aswellastwoinputsfromboththeX‐PolandCo‐PolLNBs.

4. VerifyInitialization:



Powercyclethepedestal

1. 24VDCissuppliedtothemotorsbrakestoreleasethem,then12VDCholdsthemopen

2. Elevationaxisdrivesto45degreesbasedontheICU’shorizonreference

3. CrosslevelaxisdrivestolevelbasedontheICU’shorizonreference

4. Unlimitedazimuthaxiswilldriveclockwiseuntilthehomeflagandsensormakecontact



Ifanyofthesestepsfailverifythatthe4012’sProfile1settingisconfiguredcorrectlyandsavestotheICU.Adriveissue,

pedestalerrororerrorLEDwillrequirefurthertroubleshooting.



Field Service Procedure – Replacement ICU PCB Kit, 4012



Page2of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



5. ICUStatusLEDDiagnostics



AstatusLEDisinstalledontheICUmainPCBandcanbeviewedfromtheundersideoftheICUassembly.Thedifferent

colorsstatusesindicate:



SolidGreen



ICUstatusisgood.



SolidRed



ICUfaultdetection.OperationalsoftwarewillneverleavethestatusLEDsolidRED.Reprogram



theICUsoftware.ReplacetheICUmainPCB.



SolidOrange



Softwareupdatetothe



ICU



mainPCB



isinprocess.



BlinkingOrange



Softwareupdatetothemotor



driverenclosure(throughthe



ICU)isinprocess.



BlinkingRed



Communicationerrorwiththemotordriverenclosure.ChecktheMDEstatusLEDs.IfMDEis



good,checktoassurethattheharnessconnectionsareseatedproperly.Checkharness

connections(pin‐pin,wire‐wireandwire‐ground)forgoodcontinuity.ReplacethemainPCB.

ReplacetheMDE.

6. PedestalError(Error8):

6.1. DecodingaPedestalError.

Forthe4012antennaiftherederrorLEDisilluminatedontheMXPenterintothe“system”screenand

selecttheerroricontoviewthedisplayederror(s).

6.2. ErrorTypes.

The3typesofpedestalerrorare.....

1. ServoLimit(CL,LVandAZ)–AservolimiterrormeanstheICUmainPCBisissuingthecommandto

themotordriverenclosuretodrivetherelevantaxisharderthanitshouldundernormaloperation(the

servolimithasbeenreached).Thiscouldbewhiletheantennaistryingtomaintainitspointingangle,

orwhiletheantennaisdrivingtheaxistoatargetposition.

2. StabilityLimit–Astabilitylimiterrormeanstheantennahasmispointedfromitsdesiredpositionby

morethanhalfadegree.WhenastabilitylimiterrorisflaggedonaVSATantennatheMXPwillsend

theTXMutecommandtoinhibitthetransmitfunctionofthesatellitemodem(It’scommontoseethe

servolimitandstabilitylimiterrorstogether).

3. AZReferenceError–Anazimuthreferenceerrormeansthereisacorruptreadingintheantennas

relativescale.Thiscouldbecausedbythesystemcompletinga360degreerotationwithoutthesensor

comingintocontactwiththehomeflag,thesensorcomingintocontactwiththehomeflagtooearly,

oraphysicalproblemsuchasthechainslippingonthemotorpulleyorthepulleyslippingonthemotor

shaft.



Field Service Procedure – Replacement ICU PCB Kit, 4012



Page3of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



6.3. TroubleshootingPedestalErrors–ServoLimitandStabilityLimit.

1. Reinitializethepedestal;doesitdrivecorrectlyoratall?IfnoneoftheaxisdriveverifytheN0orProfile

settingisconfiguredcorrectlyforyourmodelofantenna.

2. Verifythebalanceoftheantennaandcheckforphysicalrestrictionsonthepedestal–Iftheaxisisn’t

correctlybalancedtheICUwillbeoutputtingadditionaldrivecommandstomaintaintheantennaslevel

position.

3. Ifthemotorisn’tdrivingcorrectlyornomotordriveispresent,testthemotorforfaultsusingthebelow

procedure.Ifyoufindthemotorisdefectivereplaceitandthentestthefunctionofthemotordriver

enclosure.Iftheaxisstillfailstodrivecorrectlythemotormayhavedamagedit.Replacethemotor

driver.

6.4. TroubleshootingPedestalErrors–AzimuthReferenceError.

1. Reinitializethesystemandverifythesensorcomesintocontactwiththehomeflagasthesystem

drivesclockwiseinazimuth(theLEDwillilluminate).Ifnotverifyifthehomeflag/sensorispresent,if

correctthenthereisasensor/feedbackfailure.

2. Drivetheazimuthaxisin90degreeincrementsandverifythattheantennapointscorrectlyandthat

theMXPdisplaysthecorrectrelativeposition.Alsoverifythatthereisnophysicalrestrictiononthe

azimuthaxissuchasthechainslippingonthemotorpulleyorthepulleyslippingonthemotorshaft.

7. TestTheMotor:

Checkcontinuitybetweenground(themotorconnectorbackshell)andthe3driveroutputsonpins1,2and3of

theharness.

Nowcheckcontinuitybetweenpins4,5,6,7,8andtheground(themotorconnectorbackshell).

Alsocheckbetweentheindividualpins1,2,3andtherestofthepins(i.e.testpin1topin4,5,6,7,8andsoon,

notbetweenpins1and2,1and3or2and3).

Ifthereisanycontinuitymeasuredonthestepsmentionedabove,themotorisdefective(whichwouldbe

highlightedbythediagnosticLEDsontheMDE).Theantennasoperationshouldbeverifiedwithareplacement

motor.Ifnormaloperationdoesn’treturntheMDE/ICUwillrequirefurthertroubleshooting.



Field Service Procedure – Replacement ICU PCB Kit, 4012



Page4of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



8. VerifyStabilization:

Thepurposeofthisprocedureistophysicallymovethesystemsaxisunderstaticconditions,introducingerrorintothe

ICU’scontrolloop,andthenverifythesystemisabletoreturntoitslevelposition(stabilizeitself).Thesetestscanbe

performedbymonitoringthesensoroutputsusingDacRemPorthe4012graphsscreenandbyphysicallymovingthe

antennaandobservinghowitresponds.



1. TurntrackingoffandopentheDISP_VscreenofDacRemPoraccessthegraphsscreenofthe4012GUI.The

softwarewillnowplotthelevelpositionoftheLVandCLMEMsensors.Observeforanyabnormalities.

2. VerifyCrossLevelresponse:

Standingbehindthesystem,pushthecrosslevelbeamdowntotheleftandholditinposition.VerifythattheCL

tracemovesdownanequalamounttothemovementexertedontheaxis.Releasetheaxisandverifythatthetrace

andsystemaxisbothreturnbacktotheiroriginalpositionsinstantly,withoutdeviatingortakingtimetosettle.

Nowpushthecrosslevelbeamdowntotherightandholditinposition.VerifythattheCLtracemovesupanequal

amounttothemovementexertedontheaxis.Releasetheaxisandverifythetraceandsystemaxisbothreturn

backtotheiroriginalpositionsinstantly,withoutdeviatingortakingtimetosettle.

3. VerifyLevel(Elevation)response:

Pushthereflectorupinelevationandholditinposition.VerifythattheLVtracemovesdownanequalamountto

themovementexertedontheaxis.Releasetheaxisandverifythetraceandsystemaxisbothreturnbacktotheir

originalpositionsinstantly,withoutdeviatingortakingtimetosettle.Pushthereflectordowninelevationandhold

itinposition.VerifythattheLVtracemovesupanequalamounttothemovementexertedontheaxis.Releasethe

axisandverifythetraceandsystemaxisbothreturnbacktotheiroriginalpositionsinstantly,withoutdeviatingor

takingtimetosettle.

4. Inthetraceshouldlooksimilartothebelowimage.Notehowaftereachmovementthesystemreturnstoitslevel

positionefficientlywithouttakingtimetosettle.Shouldthesystemtaketimetosettle,ornotstabilizetothe

originalposition(notnecessarilyontheredline)thenthisisanindicationthattheantennaisn’tmaintainingits

horizonreferencecorrectlyandfurthertroubleshootingwillneedtobeundertaken.





Field Service Procedure – Replacement ICU PCB Kit, 4012



Page5of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



9. RateSensorMonitoring:

RatesensoroutputscanalsobemonitoredusingtheDISP_WscreenofDacRemPorfromthegraphsscreenofthe4012

GUItoverifyanydeviationsunderstaticconditions.Thetracesshouldremainconsistent;anydriftingorspikesarean

indicationthesensorsvoltageoutputischangingandthesensorisdefective(providednoforcesarebeingexertedonthe

system).



10. AzimuthTargeting:

Shouldtheantennahaveissuestargetinginazimuth,suchasnotaccuratelyfindingthesatelliteorrepeatedlyfindingthe

satelliteindifferentazimuthpositions,thenit’simportanttodiagnoseifthesystemismispointinginazimuthorrelative.

Relativefeedbackfromtheazimuthencodercanbeverifiedbyinitializingthesystem,verifyingitcalibratesitself

correctly,andthendrivingthepedestalclockwisein90degreeincrementsovera360degreerotation.Notethatthe

systempointscorrectlyrelativetothevesselandthatnoazimuthreferenceerrorisflaggedbytheICU.Amechanical

problemsuchasthebeltslippingonthesprocketcouldalsocausethiskindoferror.

Ifthesystemkeepsfindingthesatelliteatdifferentazimuthpositionsbutatthesamerelative,thentheencoderis

functioningcorrectlyandtheazimuthratesensoriscalculatingthemovementincorrectlycausingtheantennato

mispoint.

11. Drift:

Ifaratesensoris“drifting”itsnominalvoltageoutputhaschangedfromthecorrect2.5VDC.Thiswillcauseerrorinthe

axiscontrolloopandcausetheantennatomove.Itismorecommontoseethisdriftintheazimuthaxisasthecrosslevel

andelevationaxisbothhavealongtermreference,providedbythetiltsensor.However,shouldtheratesensorsdriftbe

largeenough,itcanover‐compensatethetiltsensorandthesystemwilldriveintooneofthecrosslevelorelevationend

stops.

Toverifyifthesystemisdriftinginazimuth,turntrackingoffandmonitortherelativeposition.Understaticconditions,

whenthevesselsheadingisunchanged,therelativecountshouldremainstationary.Iftherelativevaluebeginsto

changefromitscurrentposition,theazimuthratesensorisdrifting,introducingerrorintotheaxiscontrolloop.

IftheratesensorsarecheckedasOK,ashipsgyrocaninducedrift.ThiswillintroducelooperrorintotheICUcontrolloop

andcausetheantennatodrift.Ifit’ssuspectedtheheadingiscausingtheantennatodriftthesystemcanbesetto

satellitereferencemodetouncouplethegyrocompassfromthecontrolloop.

*Note:IftheICUandgyrocompassaredisplayingthesameheadingreadingthisisn’tanindicationthattheheading

valueiscorrect,onlythattheICUisreadingtheinformationcorrectly. 

Field Service Procedure – Replacement ICU PCB Kit, 4012



Page6of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



12. VerifyPolDrive:



AsthepolauxrelayisintegratedintotheICUmainPCBafaultwiththepolalignmentcouldpotentiallybecausedbythis

PCB.Ifnopoldriveispresentsetthepolsettingtomanualand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.



Iftheharnessconnectionsaregood,thentheICUmainPCB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24VDCtodrivethepolmotorbasedontheantenna

targeting,achangeinthevesselsGPSpositionoroperatorinputs.TheICUmainPCBwilldrivethepolmotor,whichwill

rotatethefeedassemblyuntilthecorrectoutputfromthepothasbeenreceived.Atwhichpointthefeedwillbeinthe

optimum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.

13. CommunicationDiagnostics(EoC):

TheMXPandICUbothcontainadiagnosticLEDtoverifythestatusofthesystemscommunications.OneoftheEoC

(EthernetoverCoax)LEDswillblinktoverifythestatusofthecommunicationsbetweentheADEandBDE.Basedon

whichunit(MXPorICU)hassenttheverificationcommandwilldependonwhichoneoftheEoCLED’sisblinking,if

neitheroftheLEDsareblinkingthenfurtherdiagnosticsneedstobeundertaken.



Field Service Procedure – Replacement ICU PCB Kit, 4012



Page7of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



14. ReplacingtheICUmainPCB:

14.1. Tools.



5/16”Wrench/SpannerorSocket

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

Apairof7/16”Wrenchesofa7/16”WrenchandSocket

#1PhillipsScrewdriver

3/16”Socket

Loctite248



14.2. Procedure.

ProcedureforreplacingtheICUPCB,SeaTelkitpartnumber:136818(ICUPCBpartnumber:133368‐1).



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

procedure.

1.DisconnecttheGPSantennasRJ‐45connectorfrom

theICU.





2.DisconnecttheACpowerinputsocketfromtheICU.



3.DisconnecttheRFpowerconnectionfromtheICU.



Field Service Procedure – Replacement ICU PCB Kit, 4012



Page8of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



4.Disconnectthe3SMAcablesfromtheICUusinga

5/16”wrench.



5.Usinga2mmflatbladescrewdriverdisconnecttheD‐

subconnectorsfromtheICU.



6.Usingapairof7/16”wrenches(orawrenchandsocket)

undothe4setsofhardwaresecuringtheICUtothe

elevationpanandremovethedefectiveICU.Savethe

hardwareforfutureuse.

*Note:DuetoweightoftheICUremovingitwillaffect

thebalanceofthepedestal.Supportthesystemincross

levelastheICUisremoved.



7.Usinga#1Phillipsscrewdriverremovethe11screws

securingthelidoftheICU.Savethehardwareforfuture

use.



8.Usinga3/16”socketremovethestandoffssecuringthe

J6,J7,J9andJ10D‐subconnectors.Savethehardware

forfutureuse.



Field Service Procedure – Replacement ICU PCB Kit, 4012



Page9of12



Document No

136831 Rev A

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

consent of Sea Tel, Inc. 



9.Usinga5/16wrenchorsocketremovethe3setsof

hardwarefromthesocketconnectorsfortheLNBsand

rotaryjoint.Savethehardwareforfutureuse.



10.Usinga7/16”wrenchdisconnecttheright‐handF‐

connectorfromthetrackingreceiver.

*Note:Theleft‐handconnectorcanbeleftattached



11.DisconnecttheribboncablesfromtheICUmainPCB.



12.DisconnecttheDCpowerIDCconnectorfromtheICU

mainPCB.



13.Usinga#1Phillipsscrewdriverremovethescrews

securingtheICUPCBmountingbrackettotheenclosure

andremovethePCBassembly.Savethehardwarefor

futureuse.



Other manuals for 4012

Table of contents

Other Sea Tel Antenna manuals

Sea Tel

Sea Tel Coastal 24 User manual

Sea Tel

Sea Tel ST88-21 C/Ku-Band TVRO User manual

Sea Tel

Sea Tel 6003A User manual

Sea Tel

Sea Tel ST88-21 C/Ku-Band TVRO User manual

Sea Tel

Sea Tel 9707D-70 C-BAND TX User manual

Sea Tel

Sea Tel 4012 User manual

Sea Tel

Sea Tel DTV04 User manual

Sea Tel

Sea Tel 5012-91 User manual

Sea Tel

Sea Tel 2406 User manual

Sea Tel

Sea Tel ST88 User manual

Sea Tel

Sea Tel 9711 C User manual

Sea Tel

Sea Tel 4012 GX KU-BAND User manual

Sea Tel

Sea Tel 9497B-1 User manual

Sea Tel

Sea Tel ST24 Quick start guide

Sea Tel

Sea Tel Cobham 4009-91 MK3 User manual

Sea Tel

Sea Tel 6012-33 Instruction Manual

Sea Tel

Sea Tel 6006C User manual

Sea Tel

Sea Tel 4012 GX KU-BAND User manual

Sea Tel

Sea Tel SERIES 10 User manual

Sea Tel

Sea Tel 9797B-76 User manual

Sea Tel

Sea Tel Base Exit User manual

Sea Tel

Sea Tel ST94-21 User manual

Sea Tel

Sea Tel ST144-21 User manual

Sea Tel

Sea Tel 6012-12w User manual

Popular Antenna manuals by other brands

Alfa Network

Alfa Network APA-L01 Specifications

Naval

Naval PR-422CA Operation manual

Feig Electronic

Feig Electronic ID ISC.ANTH200/200 Series manual

TERK Technologies

TERK Technologies TV44 owner's manual

Directive Systems & Engineering

Directive Systems & Engineering DSE2324LYRMK quick start guide

HP J8999A instructions

MobilSat

MobilSat MSP-S Mounting instructions

Steren

Steren ANT-UHF 13 instruction manual

Novatel

Novatel 600-G User information

Radio Shack

Radio Shack Amplified VHF/UHF/FM Indoor Antenna owner's manual

TRENDnet

TRENDnet TEW-AO12O Specifications

Radio Shack

Radio Shack 15-1837 owner's manual

CommScope

CommScope CMAX-OMFX-43M-I53 Installation instruction

Ramsey Electronics

Ramsey Electronics DAP25 Kit assembly and instruction manual

COBHAM

COBHAM SAILOR 800 VSAT Replacement procedure

Trango Systems

Trango Systems AD900-9 Specification sheet

Steren

Steren ANT-100 user manual

Proxim

Proxim 5054-PA-23 quick start guide