Sea Tel Base Exit User manual

Procedure, Field Replacement, Level Cage Kit, Base Exit

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Page1of9

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Document No

135266 Rev B

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levelcageassembly.

2. Checklist:

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VerifyRemoteTilt

VerifyInitialization

VerifySensorOutputsusingDacRemP

AzimuthandRelativeTargeting

DriftandSensorMonitoring

3. TheoryofOperation:

Thelevelcagecontains4sensors.Theseareafluidfilledtiltsensorwhichisusedasthesystemshorizonreference(level

position)andlongtermstabilizationreference,and3solidstateratesensors,oneforeachaxiswhichactsasthe

antennasshorttermstabilizationreference.Afaultysensorinsidethelevelcagewillcausetheantennatolosestability

andmispointfromthesatelliteunderdynamicconditionsalthoughthesystemmayappeartobeoperationalintheport

whenthereisnomotiontocounteract.Thisdocumentwillrunthroughtestingthesensorsinsidethelevelcage,

replacingthelevelcageassemblyandcalibratingthesystemsremotetiltsetting.

4. VerifyRemoteTilt:

Ifthepedestalishavingstabilityproblemsfirstlychecktheremotetiltsettingbylookingatthelevelbubbleontopofthe

levelcage(note:oldersystemsdidn’thaveabubbleinstalledontopofthelevelcage).Ifthebubbleisn’tascloseto

centralaspossibletheremotetiltsettingisn’tcorrectlycalibrated,meaningtheratesensorswon’tbecorrectlyaligned

withtheiraxis.ThiswillcausetheratesensorstooutputincorrectfeedbackintothePCUscontrolloop,potentially

causingastabilizationissue.Calibratetheremotetiltsettingaspertheinstructionsattheendofthisdocumentand

continuetotestthelevelcageusingthefollowprocedures.

5. VerifyInitialization:

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Powercyclethepedestal

1. Brakesrelease(ifapplicable)

2. Levelcagedrivestoitsendstop,thenbacksoffexactly45degrees

3. Elevationaxisdrivesto45degreesbasedonthelevelcageshorizonreference

4. Crosslevelaxisdrivestolevelbasedonthelevelcageshorizonreference

5. Unlimitedazimuthsystemsdriveclockwiseuntilthehomeflagandsensormakecontact

6. Limitedazimuthsystemsdriveclockwiseintotheazimuthendstop,thenbackoffto630degreesof

relative

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Ifanyofthesestepsfail,ortheACUreportsmodel"xx03/xx04",theantennasN0parameterneedscalibratingand

verifieditsavescorrectly.Adriveissueorpedestalerrorrequiresfurthertroubleshooting.

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Procedure, Field Replacement, Level Cage Kit, Base Exit

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Page2of9

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Document No

135266 Rev B

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. VerifyStabilization:

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

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

canbeperformedbymonitoringthesensoroutputsonDacRemPoralsobyphysicallymovingtheantennaandobserving

howitresponds.

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1. TurntrackingoffandOpentheDISP_VscreenofDacRemP,itwillnowplotthelevelpositionofthetiltsensor.

Alternativelyobservethepedestal.Normaltraceis+/‐4divisionsfromredline.

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2. VerifyCrossLevelresponse:

Pushthecrosslevelbeamdowntotheleft(CCW)andholditinposition.VerifythattheCLtraceonDacRemP

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

returns(orthesystemsaxisreturns)backtoitsoriginalposition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onDacRemP

movesupanequalamounttothemovementexertedontheaxis.ReleasetheAxisandverifytheDacRemPtrace

returns(orthesystemsaxisreturns)backtoitsoriginalpositioninstantly,withoutdeviatingortakingtimetosettle.

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

PushtheReflectorupinElevation(CCW)andholditinposition.VerifythattheLVtraceonDacRemPmovesdown

anequalamounttothemovementexertedontheaxis.ReleasetheAxisandverifytheDacRemPtracereturns(or

thesystemsaxisreturns)backtoitsoriginalpositioninstantly,withoutdeviatingortakingtimetosettle.Pushthe

ReflectordowninElevation(CW)andholditinposition.VerifythattheLVtraceonDacRemPmovesupanequal

amounttothemovementexertedontheaxis.ReleasetheAxisandverifytheDacRemPtracereturns(orthe

systemsaxisreturns)backtoitsoriginalpositioninstantly,withoutdeviatingortakingtimetosettle.

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IfusingDacRemPthetraceshouldlooksimilartothisimage,notehowaftereachmovementthesystemreturnstoits

levelpositionefficientlywithouttakingtimetosettle.

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Procedure, Field Replacement, Level Cage Kit, Base Exit

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Document No

135266 Rev B

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

consent of Sea Tel, Inc. 



7. RateSensorMonitoring:

RatesensoroutputscanalsobemonitoredusingtheDISP_WscreenofDacRemP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).Normaltraceis+/‐1division

fromredline.

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8. AzimuthTargeting:

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

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

feedbackfromtheAZ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,notingthatthesystempoints

correctly(bow,starboard,aft,port,bowandstarboard)andthatnoAZreferenceerrorisflaggedbythePCU.A

mechanicalproblemsuchasthebeltskippingonthesprocket,oranotherphysicalrestriction,couldalsocausethiskind

oferror.Skewingtheantennainazimuthbyholdingtherightorleftarrowkeytodrivetheantennaslowlymayalso

presentanissue.

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.

9. Drift:

Anotherfailurewhichcanoccurisifaratesensorstartsdrifting.Thismeansthesensorsvoltageoutputdeviatesfrom

whatthePCUisexpecting(2.5VDC),whichintroduceserrorintothecontrolloop.It’smorecommontoseethisinthe

AzimuthaxisastheCLandELaxishavethetiltsensorastheirlongtermreference(althoughshouldtheratesensorsdrift

belargeenoughtooverpowerthetiltsensoryouwouldseethesystemdrivingintooneoftheCLorELendstops).

ToverifyifthesystemisdriftinginAzimuthturnofftrackingandmonitortherelativeposition,understaticconditions

(i.e.whenthevesselsheadingisn’tchanging),itshouldremainstill.Iftherelativevaluebeginstoincrease/decreasefrom

itsnominalpositionthentheazimuthratesensorisdrifting,feedingerrorintothePCU’scontrolloopwhichiscausing

thePCUtobelievethevesselsheadingischangingandinturndrivingtherelativeintheoppositedirectionto

compensate. 

Procedure, Field Replacement, Level Cage Kit, Base Exit

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Document No

135266 Rev B

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

consent of Sea Tel, Inc. 



10. Diagnostics:

Anyincorrectreadingsfromtheabovetestswouldrelatetoanerrorintheantennascontrolloopcausingthesystemto

notstabilizecorrectly.Themostlikelycauseofthisisadefectivesensorinthelevelcage.Thenextstepwillbetoreplace

thelevelcageandrepeatthetestwhichtheantennafailedtoverifyifthesystemisnowfunctioningcorrectly.

Shouldtheproblempersistotherpossibilitiesareabadconnectiononthereferenceharnessbetweenthelevelcageand

PCUcorruptingthefeedback,orpossiblythePCUitselfnotcalculatingthefeedbackcorrectly.Howeverasthelevelcage

isthemostlikelycomponenttobecausingthisissuereplacingitisthefirststepinthetroubleshootingprocedure.

Oncetheproblemhasbeenrectifieditsgoodpracticetorefittheoriginallevelcageandseeifthefaultreturns.It’s

possiblethattherewascorrosiononthepinsofthereferenceharnessandbyconnectingthereplacementlevelcagethe

pinshavebeencleaned,allowinggoodmetaltometalcontactandgivingtheimpressionthatreplacingthelevelcage

rectifiedthefault(cleaningthepinsonthePCUendofthereferenceharnessisalsoadvisable).

11. FurtherInformation:

Shouldthesystemfailtotargetthecorrectelevation(physicallypointingatadifferentpositiontothereadingonthe

DAC)orhaveissuesdrivingpastacertainelevationpositionthenthemostlikelycauseisadefectivelevelcagemotor.

Ifthesystemisdisplayingapedestalerror(error8)thenthereisadriveissuewiththeantennaandattentionwillneedto

bepaidtothemotorandmotordriver(servoamp)fortherelevantaxis.Adefectivelevelcagewon’tflaganerror8asthe

PCUdoesn’tknowifthefeedbackfromthelevelcageiscorruptwhichiswhytheantennawillmispointifthelevelcageis

defective.

Anotherpotentialissuewhichcouldcausetheantennatolosethesatelliteisifthevesselsgyrocompassisdrifting,

accumulatingerrorwhichisthenfedintothecontrolloop.ThiscanbeverifiedbyrunningaDacRemPlogfileatseato

monitorthepedestalsreadingswhentheAGCdrops,orbyputtingthesystemintosatellitereferencemodetobypass

thegyrofromtheazimuthcontrolloop.

12. 2406LevelCageConfiguration:

Tousethelevelcage(partnumber:122937‐1)onthe2406pedestal,itwillneedtobeconvertedintoa122937‐2.Thisis

donesimplybyreconfiguringtheendstopsonthebackofthelevelcageassemblyasperthebelowimage.Thestandard

122937‐1levelcageshastheendstopsontheleft‐handside,thesewillneedtobemovedtotheright‐handsidetouse

thelevelcagesonthe2406pedestal.



122937‐1122937‐2

Procedure, Field Replacement, Level Cage Kit, Base Exit

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Document No

135266 Rev B

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

consent of Sea Tel, Inc. 



13. XX06LevelCageInstall:

*Note:Howthenylocknutisinstalled,tensioningthecentrecollarofthebearing,preventingthelevelcagefrommoving

fromsidetosideonthespindle,notovertightenedsoitcanmovesmoothly.



14. ReplacingtheLevelCageAssembly:

14.1. Tools.



2mmFlatBlade(Terminal)ScrewDriver

#1PhillipsScrewdriver

½”Wrench/Spanner

14.2. Procedure.

Procedureforreplacingthelevelcageassembly,SeaTelkitpartnumber:135343(levelcageassemblypartnumber:

122937‐1)andtensioningthelevelcagebelt.TheprincipalisthesamefortheXX06levelcage,althoughit’sinstalled

inadifferentorientation(asshownabove).



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

procedure.

1.Usinga2mmflatbladescrewdriverloosenthescrews

securingthereferenceharnessD‐Subconnectortolevelcage.



Procedure, Field Replacement, Level Cage Kit, Base Exit

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Page6of9

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135266 Rev B

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

consent of Sea Tel, Inc. 



2.Usinga#1Phillipsscrewdriver,loosenthefourscrews

attachinglevelcagemotortotheELpan(donotfully

remove).

3.Slidethemotortowardsthereflectorandremovethebelt

fromlevelcagemotorsprocket.



4.Usinga½”socketorwrenchremovetheNylocknut

securingthelevelcagetothespindle.



5.Takecarenottoremovethelevelstandoffspacerfromthe

spindle.



6.Installthereplacementlevelcageontothespindle,slipping

thebeltoverthelevelcagepulleyandmakingsureitsend

stopsarealignedcorrectly.Secureitwiththe1/2”Nylocknut,

tightenedsoitslightlypreloadsthebearings.

7.Rotatethelevelcagebyhandandverifyithas90degreesof

motionandthatthecagerotatesfreelywithoutrubbing

againsttheELpan.



8.Placethebeltonthelevelcagesprocketandthenslipit

overthesprocketofthelevelcagemotor.



Procedure, Field Replacement, Level Cage Kit, Base Exit



Page7of9



Document No

135266 Rev B

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

consent of Sea Tel, Inc. 



9.Tensionthebeltbyslidingthemotorassemblybyhand

awayfromlevelcageandtightenoneofthefourscrews.



10.Increasethebelttensionuntilthebeltcanonlybeeasily

twistedjust¼turnwithyourfingers.

11.Ifthebelttensionistootight/loseadjustuntilcorrectand

thensecurethemotor.



12.PlugthereferenceharnessbackintothelevelcageD‐Sub

connectorandtightentheretainingscrews(noneedto

Loctiteassplitwashersareinstalledontheharness).





Procedure, Field Replacement, Level Cage Kit, Base Exit

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Page8of9

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Document No

135266 Rev B

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

consent of Sea Tel, Inc. 



15. CalibratingtheRemoteTiltSetting:

Thisprocedureisrequiredtocalibratethelevelcagesothatallthesensorswillbeaccuratelyalignedtotheiraxis.The

fluidfilledtiltsensorprovidesatwodimensionalhorizonreference.Thesystemisnotabletoautomaticallycalculatethe

exactcentervalue,thereforeitisnecessarytoperformthisproceduretomanuallyenteranyoffsetrequiredtomakesure

thePCUreceivesatruehorizonreference.



1. Turndishscanoff:

EnterintotheSetupMenubypressingandholdingthearrowstogetheruntiltheELTrimorAutoTrim

parameterisdisplayed.

Usethearrowkeytoscrollthroughthemenuuntilthedishscanwindowisdisplayed.

Pressthearrowtoactivatethewindowandthenpressthearrow,followedbythebuttontoturn

dishscanfromontooff.

*Note:Whenyoupressthearrowtoturndishscanoffyouwon’tseethedisplaychangeuntilyoupressthe

button.



(Steps2‐7requiresassistancetoobserveandoperateantennasimultaneously)



2. EnterintotheSetupMenubypressingandholdingthearrowstogetheruntiltheELTrimorAutoTrim

parameterisdisplayed.



3. PushthearrowkeyuntiltheRemoteTiltwindowisdisplayed.



4. PushthearrowkeytoactivatetheRemoteTiltsetting.



5. Usethearrowkeystopositionthebubbleasclosetothecenteraspossible.Eachpressofanarrowkeyonthe

directionalpadwillmovetheRemoteTilt½adegree.Itisadvisedthatyouonlypressthebuttononceandwaitfor

theaxistomovebeforepressingitagain.



Whenstandingbehindtheantennalookingatthebubble,ifthebubbleisovertotheright,youneedtopressthe

(right)arrowtobringthebubbleintothecenter.Ifthebubbleisdowntowardsyou,youneedtopressthe

(down)arrowtobringittowardsthecenter.Ifthebubbleistotheleft,youneedtopressthe(left)arrowandif

thebubbleisuptowardsthetop,youneedpressthe(up)arrowtomoveittowardsthecenter.



Procedure, Field Replacement, Level Cage Kit, Base Exit

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Page9of9

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Document No

135266 Rev B

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

consent of Sea Tel, Inc. 



Whencorrectthebubbleshouldbeasclosetothecenterofthefluidaspossible



6. WhenthebubbleisascentralaspossiblepressthebuttontodeactivatetheRemoteTiltsetting.



7. Turndishscanon:

EnterintotheSetupMenubypressingandholdingthearrowsuntileithertheELTrimorAutoTrim

parameterisdisplayed.

Usethearrowkeytoscrollthroughthemenuuntilthedishscanwindowisdisplayed.

Pressthearrowkeytoactivatethewindowandthenpressthearrowkey,followedbythebuttonto

turndishscanfromofftoon.

*Note:Whenyoupressthearrowtoturndishscanonyouwon’tseethedisplaychangeuntilyoupressthe

button.



8. SavetheRemoteTiltsettinginthePCU:

PressthearrowkeyuntiltheRemoteParameterswindowisdisplayed.

Pressthearrowkeytoactivatethewindowfollowedbythebutton(you’llseeaconfirmationonthe

displaysaying“Saved”).



9. AsgoodpracticemakeanoteofyourN4andN5parametersonceyouhavecorrectlysettheremotetilt.TheN4and

N5parametersareanumericreadoftheremotetilt.Todothisgototheremotecommandwindowandkeyin

N4999toreadtheCLsetting,followedbyN5999toreadtheELsetting.



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