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Orbit AL-7103 M & T - Print
Orbit AL-7103 M & T - Print
Orbit AL-7103 M & T - Print
AL-7103 MKII
1.15m (45) Ku-Band/X-Band Antenna Maritime Stabilized VSAT System
Copyright
2011 Orbit Communication Ltd. All rights reserved. All product names are trademarks of Orbit Communication Ltd. Other names are the property of the respective owners. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, electronic or otherwise, without the prior written permission of Orbit Communication Ltd. Disclaimer of Warranty Orbit Communication Ltd has made every effort to ensure the accuracy and relevancy of the material in this document. It is expected that all sections of this document will be read thoroughly and that all information and procedures should be fully understood. However, Orbit Communication Ltd assumes no responsibility for any errors that may appear in this document, and reserves the right to make changes to the document without notice. Orbit Communication Ltd makes no warranty of any kind in regard to this document, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Orbit Communication Ltd disclaims any responsibility for incidental or consequential damages in connection with the furnishing, performance or use of this document. Parts of this document may be based on hardware or software developed by third-party vendors. Orbit Communication Ltd disclaims any responsibility for the accuracy of this document with respect to such hardware and software, and assumes no responsibility for incidental or consequential damages arising due to discrepancies between this document and such hardware or software.
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Certifications
Orbit Communication Technologies Ltd. is an ISO 9001 registered company. Registration License No. 27870, issued May 1st, 2005.
ORBIT AL-7103 Stabilized Marine Satellite Communication System is in conformity with the appropriate standards: ISO 12100-2:2003, EN 60204-1:1997, EN 614-1:1995, IEC 60945:2002, ETSI EN 302340.
The AL-7103 System is granted EUTELSAT Type Approval as standard earth station. Type Approval Certificate Registration Number: EA-A033.
The AL-7103 System is granted INTELSAT Type Approval, as GVF earth station. Type Approval Certificate Registration Number: GVF/IA 200FLT, standards K2 & G.
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Date
June 2011
Comments
Initial version
Content
Title Page and Copyright Certifications Revision History and Control About this Manual Safety Precautions Table of Contents List of Figures Overview Replacing System Components Updating the System Software Troubleshooting Preventive Maintenance
Change No.
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Text Conventions
Style Text Indicates Normal descriptive text Words or figures that appear on the screen or that should be typed; the name of a file or directory A key to be pressed The name of a software or hardware component The description of a procedure Example Contents
Text
System Status
<Text>
TEXT
<ESC>
ANTENNA
To configure
Notations
Indicates the safest method of installation or operation that must be adhered to.
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Safety Precautions
The following general precautions apply to the installation, operation and servicing of the system. Specific warnings appear throughout the manual where they apply, and may not appear in this summary. Only qualified and trained personnel should perform installation, operation, and maintenance of this equipment. Before entering the RADOME for maintenance purposes, shut off the main the ADE POWER BOX. Take extra care when handling the ADE POWER BOX, SLIP RING, and POWER SUPPLY UNIT which are all connected to 110/220 VAC and when handling the SERVO DRIVE MODULES which are connected to 51 VDC. The system conducts potentially harmful voltages when connected to the designated power sources. Never remove equipment covers except for maintenance or internal adjustments. Keep clear of the moving ANTENNA at all times. The POSITIONER is equipped with high-torque motors that generate considerable force.
power to the system from the ships electrical panel. Upon entry, switch off
When units are connected to the chassiss ground (to prevent shock and similar hazards), the chassiss ground conductor must not be removed. Although the RADOME is not heavy, care should be taken when lifting it as it acts as a sail under windy conditions. At least two people should handle the RADOME during installation. To prevent shock or fire hazard when sub-units are open or cables are disconnected, do not expose the equipment to rain or moisture. Avoid making unauthorized modifications to the circuitry. Any such changes to the system will void the warranty. Do not disconnect cables from the equipment while the system is running.
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System interfaces require high-quality connectors and cables. Use only Orbit-authorized parts for repair.
Radiation Safety
The following figure illustrates the safety distances for an OrSatTM AL-7103 MKII system equipped with 8W BUC. For systems equipped with a 16W BUC, safety distances should be multiplied by approximately 1.5.
The values illustrated in this diagram are driven by ACGIH and ICNIRP guidelines, for occupational use.
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Table of Contents
1 2 Overview .........................................................................................................................1 Replacing System Components ......................................................................................2 2.1 2.2 2.3 2.4 Before you begin ......................................................................................................2 List of Tools for LRU Replacement Procedures ........................................................3 Removing/Replacing the Radome ............................................................................4 Replacing the IMU....................................................................................................4 Removing the IMU ........................................................................................... 4 Reinstalling the IMU ......................................................................................... 6 Configuring the IMU ......................................................................................... 6 Inspecting the IMU-Slip Ring Cable .................................................................. 7 Rerouting the IMU-Slip Ring Cable................................................................... 7
Replacing the SBC ...................................................................................................9 Preliminary Procedures .................................................................................... 9 Removing the SBC..........................................................................................10 Reinstalling the SBC .......................................................................................11 Resetting the SBC IP address .........................................................................12 Reconfiguring the System ...............................................................................12
Replacing the PSU .................................................................................................13 Removing the PSU..........................................................................................13 Reinstalling the PSU .......................................................................................14 Post-Assembly System Verification .................................................................15
Replacing the GPS Antenna...................................................................................16 Removing the GPS Antenna ...........................................................................16 Reinstalling the GPS Antenna .........................................................................17
2.7.1 2.7.2
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2.7.3 2.8
Replacing the ADMx...............................................................................................18 Removing the ADMx .......................................................................................18 Reinstalling the ADMx .....................................................................................20 Post-Installation System Verification ...............................................................21
Replacing the DC Inserter ......................................................................................22 Removing the DC Inserter ...............................................................................22 Reinstalling the DC Inserter.............................................................................23 Post-Installation System Verification ...............................................................24
Replacing the Splitter .............................................................................................25 Removing the Splitter ......................................................................................25 Reinstalling the Splitter....................................................................................26 Post-Installation System Verification ...............................................................26
Replacing the X-Axis SDM .....................................................................................27 Removing the X-Axis SDM ..............................................................................28 Reinstalling the X-Axis SDM............................................................................30 Axis Alignment Verification ..............................................................................32
Replacing the Y-Axis SDM .....................................................................................38 Removing the Y-Axis SDM ..............................................................................39 Reinstalling the Y-Axis SDM............................................................................41 Axis Alignment Verification ..............................................................................43
Replacing the Z-Axis SDM .....................................................................................44 Removing the Z-Axis SDM ..............................................................................45 Reinstalling the Z-Axis SDM ............................................................................48 Axis Alignment Verification ..............................................................................51
Replacing the LNB ..........................................................................................52 Replacing the RF Chain ..................................................................................54 Replacing the 4W BUC ...................................................................................56 Replacing the 8W BUC ...................................................................................59 Replacing the 16W BUC .................................................................................63
Updating the System Software ......................................................................................71 3.1 3.2 3.3 3.4 Updating the CCU MtsLink Application ...................................................................71 Updating the SBC VxWorks Application .................................................................72 Updating the IMU Calibration File ...........................................................................74 Reconfiguring the SBC ...........................................................................................76
Troubleshooting ............................................................................................................78 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 Tracking Error Exceeds Limit .................................................................................79 Tracking Instability .................................................................................................80 Pointing to Satellite Issues .....................................................................................81 No Communication Between ADE and BDE ...........................................................82 The SBC Does Not Boot ........................................................................................83 Wrong IP Address for SBC .....................................................................................84 Blank CCU Screen .................................................................................................85 The CCU Does Not Boot ........................................................................................85 No GPS Output from the CCU................................................................................86 No GPS Position Update ........................................................................................87 GPS Communication Failed ...................................................................................88 Compass Communication Failed ............................................................................89 Axis Jamming Errors ..............................................................................................90 Polarization Axis Jamming Error.............................................................................92 Axis Encoder Errors ...............................................................................................94
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No Rx Lock ............................................................................................................96 No Tx Lock .............................................................................................................97 Missing System Files..............................................................................................99 ADE / BDE Software Mismatch ..............................................................................99 Using the Status Dump Function for Troubleshooting........................................... 100 Downloading the Status Dump Report ..........................................................100 Status Dump File Example ............................................................................100
4.20.1 4.20.2 5
Preventive Maintenance .............................................................................................. 107 5.1 5.2 Introduction ..........................................................................................................107 Health Check........................................................................................................107 Visual inspection ...........................................................................................107 System Software ...........................................................................................107 Mechanical Test ............................................................................................108 RF System Performance Test .......................................................................111 System Documentation .................................................................................111
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List of Figures
Figure 2-1: Correct Routing ....................................................................................................7 Figure 2-2: Incorrect Routing ..................................................................................................7 Figure 2-3: Correct IMU-Slip Ring Cable Routing ...................................................................8 Figure 2-4: CCU-Laptop Connection ......................................................................................9 Figure 2-5: Location of Screws on the X-Axis SDM .............................................................. 27 Figure 2-6: Cable Connections on the X-Axis SDM .............................................................. 27 Figure 2-7: Antenna after Enc Init Sequence ........................................................................ 33 Figure 2-8: Manual Axis Control ...........................................................................................33 Figure 2-9: X-Axis Reference Points.....................................................................................34 Figure 2-10: X-Axis Alignment ..............................................................................................34 Figure 2-11: Y-Axis Reference Points...................................................................................35 Figure 2-12: Y-Axis Alignment ..............................................................................................35 Figure 2-13: Z-Axis Reference Points ...................................................................................36 Figure 2-14: Pedestal X Window ..........................................................................................36 Figure 2-15: Axes Parameters Dialog Box ............................................................................ 37 Figure 2-16: Location of Screws on the Y-Axis SDM ............................................................ 38 Figure 2-17: Cable Connections on the Y-Axis SDM ............................................................ 38 Figure 2-18: Location of Screws on the Z-Axis SDM ............................................................ 44 Figure 2-19: Cable Connections on the Z-Axis SDM ............................................................ 44 Figure 3-1: MtsDock ThisHost Menu ....................................................................................71 Figure 3-2: Host Communication Dialog Box ........................................................................ 72 Figure 3-3: Connect to ACU Dialog Box ............................................................................... 73 Figure 3-4: Connect ACU Message Box ............................................................................... 73 Figure 3-5: Put Executable Command ..................................................................................74 Figure 3-6: Connect to ACU Dialog Box ............................................................................... 75 Figure 3-7: Get IMU Calibration Command........................................................................... 75 Figure 3-8: Connect to ACU Dialog Box ............................................................................... 76 Figure 3-9: Get Configuration Command .............................................................................. 77 Figure 4-1: Select Status Dump File Dialog Box ................................................................. 100 Figure 5-1: Pedestal-X Dialog Box ..................................................................................... 108 Figure 5-2: Azimuth Trajectory results ................................................................................ 109
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1 Overview
This manual contains instructions for post-installation maintenance of the OrSatTM AL-7103 MKII Maritime Stabilized VSAT System. It includes the following chapters: Replacing System Components illustrated instructions for removing and reinstalling the Line Replaceable Units (LRUs) that comprise the OrSatTM AL-7103 MKII system Updating the System Software procedures for updating the CCU and SBC operating software, IMU calibration file and SBC configuration file Troubleshooting a series of flowcharts illustrating the chain of operations to perform when solving a variety of common problems encountered during system operation Preventive Maintenance a program of procedures to be performed at regular intervals in order to ensure that the OrSatTM AL-7103 MKII system continues to function smoothly with maximum performance over time
In the following procedures, be very careful when tightening and loosening the screws with which the parts are assembled and attached to the system. Some of these screws are delicate and can be damaged by excess force. When using an Allen key, make sure to insert the key all the way into the screw head, to avoid stripping, and do not exceed the torque specified for each type of screw. Apply Loctite Threadlocker when inserting screws during the replacement process: Blue #241 for screws below 5mm in width, Red #270 for screws over 5mm. In order to loosen the screws when removing a part (with the exception of RF and SDM components), you may need to heat the screw with a blower in order to melt the Loctite.
WARNING! The Utility Outlet is connected directly to the vessels AC voltage input terminals (125 VAC / 250 VAC). Therefore, there still exists live voltage at the Utility Outlet after disconnecting the power supply to the ADE using the Mains Power On/Off Switch. Only qualified and authorized personnel are allowed to carry out system service/maintenance procedures.
Required Tools
3/16 Allen key 5/32 Allen key 8mm + 11mm Open wrench 5/32 Allen key
11mm Open wrench Phillips screwdriver Loctite 241 3/16 Allen key 5/32 Allen key
Replacing the X-Axis SDM Replacing the Y-Axis SDM and Replacing the ZAxis SDMs
3/16 open wrench Torque Meter Tie-wraps Pliers & Tie Cutter
Replacing the
6mm open wrench 7/16 open wrench Replacing the 4W BUC 3/16 Allen key Tie-wraps Tie Cutter 13mm open wrench Replacing the 8W BUC 3mm Allen key Tie-wraps Tie Cutter 8mm + 13 mm open wrench Replacing the 16W BUC 6 mm Allen key Tie-wraps Tie Cutter
Step 2 Remove the four screws securing the IMU to the RADOME BASE, using a 3/16 Allen key. Attention: In order to access the left-hand back screw, you will need to rotate the Z Axis.
5. Incorrect routing between the IMU and the ADE BASE can result in damage to the cable, due to system vibrations. To correct the cable routing, perform the following procedure.
5. Connect the cable to the IMU connector. 6. Power up the system and activate Test Traj Mode for five minutes. Verify that the cable is not squeezed or pinched at any point in the systems movement.
2. Open MTSDOCK and download the SBC configuration file (see Reconfiguring the SBC [Steps 1-5] on page 76 for instructions). 3. Download the IMU calibration file (see Updating the IMU Calibration File [Steps 1-4] on page 74 for instructions). 4. Shut down the system and power off.
Step 2 Disconnect all cables from the SBC connector panel using an 8mm Open wrench.
Step 3 Loosen the four screws securing the SBC to the BASE PLATE, using a 5/32 Allen key. Note: The screws remain attached to the SBC (captives).
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Step 2 Tighten the four screws securing the SBC to the BASE PLATE, using a 5/32 Allen key.
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12
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Step 3 Loosen the three screws securing the PSU to the BASE PLATE, using a 5/32 Allen key. Note: The screws remain attached to the PSU (Captives).
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Step 2 Tighten the three screws securing the PSU to the ADE BASE, using a 5/32 Allen key.
Step 4 Mount the GPS ANTENNA in its place on the PSU and secure it with a tie-wrap.
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Step 2 Disconnect the GPS ANTENNA cable from the SBC connector, using an 8mm Open wrench.
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Step 2 Connect the GPS ANTENNA cable to the SBC connector, using an 8mm Open wrench.
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Step 2 Cut the tie-wraps securing the cables to the ADMX mounting plate.
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Step 3 Remove the four screws securing the ADMX mounting plate to the assembly, using a 5/32 Allen key.
Step 4 Remove the four screws securing the ADMX to its mounting plate, using a 3mm Allen key.
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Step 2 Use a 5/32 Allen key to secure the ADMX mounting plate to the assembly,
Step 3 Replace the cable harness on the ADMX mounting plate and secure it with tie-wraps.
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Step 4 Connect the cables to the ADMX connectors, using a 7/16 or 8mm open wrench. Attention: If the RF cable includes a 22KHz filter, replace the filter before connecting the cable.
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Step 2 Remove the two screws securing the DC INSERTER mount to the assembly, using a 5/32 Allen key.
Step 3 Use a Phillips screwdriver to remove the four screws holding the DC INSERTER to its mounting plate.
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Step 2 Use a 5/32 Allen key to secure the DC INSERTER mounting plate to the assembly.
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Step 2 Remove the two screws securing the SPLITTER to the assembly, using a 7/64 Allen key.
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2.10.2
Step 1
Apply Loctite 241 to the two screws, and secure the SPLITTER to the assembly using a 7/64 Allen key.
Step 2 Connect the cables to the SPLITTER connectors, using a 7/16 or 11mm open wrench.
2.10.3
After replacing the SPLITTER, power up the system and verify that the modems AGC and EB/N0 have not changed and are exactly as defined in the link budget.
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2.11.1
Step 1 Cut the tie-wraps binding the cables connected to the SDM.
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Step 3 Remove the six screws securing the SDM to the assembly, using a 3/16 Allen key.
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2.11.2
Step 1 Mount the new SDM in its place and secure it to the assembly. Tighten the six screws using a 3/16 Allen key with 11N/M torque.
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2.11.3
After replacing the SDM, perform the following procedure to verify that the physical zero is properly aligned. 1. Power up the system and activate Enc Init Mode several seconds after startup (see the
AL-7103 MKII Installation and Operation Manual for instructions). When the sequence is
complete the antenna should be positioned as displayed in the following image.
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2. Enter the MTSLINK Maintenance Screen and move each axis manually until its position corresponds to that displayed in the relevant image:
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X-Axis Alignment
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Y-Axis Alignment
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Z-Axis Alignment
The distance between points A and B to the BASE PLATE should be equal. 3. Note the value of each axis movement. In the below figure, the X AXIS has been moved 1.5 in order to reach the correct physical alignment.
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4. Enter the MTSLINK Operation Screen and click Axes Parameters on the InConfig menu. The Axes Parameters dialog box appears.
5. Add the value recorded for each axis to the Encoder Offsets values, using the opposite sign. For example, the current Pedestal-X value is 0.000. For a movement of 1.5, add -1.5 to the value, for a new value of -1.5.
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2.12.1
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Step 2 Remove the six screws securing the SDM to the assembly using a 3/16 Allen key, and remove the SDM from the assembly.
Step 3
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2.12.2
Step 1 Put the new SDM in its place and secure it to the assembly. Tighten the six screws using a 3/16 Allen key with 11N/M torque.
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2.12.3
After replacing the SDM, perform the axis alignment procedure on page 32 to verify that the physical zero is properly aligned.
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2.13.1
Step 1 Cut the tie-wraps binding the cables connected to the SDM.
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Step 2 Disconnect the power cable and the three cables that pass though the SLIP-RING (ADMX, SBC, and PSU). Attention: Be very careful not to bend the RF cable. A bent cable could damage the SLIP-RING when the system is functional.
Step 3 Remove the KEY CARRIER from the Z-AXIS SDM, using a 3/16 Allen key.
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Step 4 Use a 5/32 Allen key to remove the two screws holding the T-shaped bar to the KEY CARRIER and pull out the cables.
Step 5 Remove the six screws securing the SDM to the assembly using a 3/16 Allen key. Attention: Be careful not to damage the cables.
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2.13.2
Step 1 Put the new SDM in its place and secure it to the assembly. Tighten the six screws using a 3/16 Allen key with 11N/M torque.
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Step 2 Thread the cables through the KEY CARRIER and secure the T-shaped bar. Apply Loctite 270 to the two screws and tighten them using a 5/32 Allen key with 4N/M torque. Attention: The blue LMR cable should run to the right of the T-shaped bar, and the IMU and power cables to the left.
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Step 3 Secure the KEY CARRIER to the SDM, using a 3/16 Allen key with 11N/M torque.
Step 4 Connect the power cable and the three cables that pass though the SLIP-RING (ADMX, SBC, and PSU). Attention: Be very careful not to bend the RF cable. A bent cable could damage the SLIP-RING when the system is functional.
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2.13.3
After replacing the SDM, perform the axis alignment procedure on page 32 to verify that the physical zero is properly aligned.
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When performing the following procedures, be careful not to bend or damage the highly sensitive RF cables.
2.14.1
To remove the LNB: Step 1 Disconnect the cable from the LNB connector, using a 7/16 or 7mm open wrench.
Step 2 Remove the four screws securing the LNB to the RF ASSEMBLY, using a 3mm Allen key.
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To reinstall the LNB: Step 1 Use a 3mm Allen key to secure the LNB to the RF ASSEMBLY. Attention: Make sure to replace the rubber O-Ring that seals the LNB to the WAVEGUIDE. Step 2 Connect the cable to the LNB connector, using a 7/16 or 7mm open wrench.
Post-Installation System Verification After replacing the LNB, power up the system and drive the BUC to 1dB compression (see the
AL-7103 MKII Installation and Operation Manual for instructions). Verify that the EB/N0 is
exactly as defined in the link budget.
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2.14.2
To remove the RF Chain: Step 1 Disconnect the cable from the RF CHAIN connector, using a 5/16 open wrench.
Step 2 Remove the four screws securing the RF CHAIN to the RF ASSEMBLY, using a 3mm Allen key.
Step 3 Remove the RF CHAIN. Note: If the LNB is functioning, remove the LNB and replace it on the new RF Chain (see Replacing the LNB above).
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To reinstall the RF Chain: Step 1 Use a 3mm Allen key to secure the new RF CHAIN to the RF ASSEMBLY. Attention: If necessary, replace the LNB on the new RF CHAIN. Make sure to replace the rubber O-Ring that seals the RF CHAIN to the RF ASSEMBLY. Step 2 Connect the cable to the RF CHAIN connector, using a 5/16 open wrench.
Step 3 Reconnect the cable from the RF CHAIN to the LNB. Post-Installation System Verification After replacing the RF CHAIN, power up the system and drive the BUC to 1dB compression (see the AL-7103 MKII Installation and Operation Manual for instructions). Verify that the EB/N0 is exactly as defined in the link budget.
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2.14.3
To remove the BUC: Step 1 Disconnect the cables from the BUC connectors.
Step 2 Remove the four screws securing the BUC WAVEGUIDE, using a 6mm open wrench for the SMA connector.
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Step 3 Loosen the nuts securing the four screws on the mounted brackets using a 7/16 open wrench. Remove the screws using a 3/16 Allen key.
Step 4 Remove the BUC. To reinstall the BUC: Step 1 Mount the new BUC in its place and secure it to the mounted brackets using a 3/16 Allen key and a 7/16 open wrench.
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Step 2 Replace the BUC WAVEGUIDE, and secure its four screws, using a 6mm open wrench for the SMA connector. Attention: Make sure to replace the rubber O-Ring that seals the WAVEGUIDE to the BUC.
Post-Installation System Verification After replacing the BUC, power up the system and drive the BUC to 1dB compression (see the
AL-7103 MKII Installation and Operation Manual for instructions). Verify that the EB/N0 is
exactly as defined in the link budget.
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2.14.4
To remove the BUC: Step 1 Disconnect the cables from the BUC connectors.
Step 2 Remove the two screws securing the BUC to the RF ASSEMBLY, using a 13mm open wrench and 3mm Allen key.
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Step 3 Remove the 4 screws securing the BUC WAVEGUIDE, using a 3mm Allen key.
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To reinstall the BUC: Step 1 Mount the new BUC in its place and use a 13mm open wrench to tighten the securing screws.
Step 2 Use a 3mm Allen key to secure the BUC WAVEGUIDE. Attention: Make sure to replace the rubber O-Ring that seals the WAVEGUIDE to the BUC.
Step 3 Use a 13mm open wrench and 3mm Allen key to secure the BUC to the RF ASSEMBLY.
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Post-Installation System Verification After replacing the BUC, power up the system and drive the BUC to 1dB compression (see the
AL-7103 MKII Installation and Operation Manual for instructions). Verify that the EB/N0 is
exactly as defined in the link budget.
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2.14.5
To remove the BUC: Step 1 Cut the tie-wraps binding the cables and remove them from the DISH ASSEMBLY.
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Step 3 Release the inner and outer nuts and remove the screws and washers. Attach the nuts and washers to their screws and save them for the reinstallation procedure.
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To reinstall the BUC: Step 1 Connect the Waveguide-to-SMA adapter to the BUC with M4 fasteners and an EMI O-Ring. Use a 3mm Allen key and a 7mm open wrench.
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Step 2 Use a 2.5mm Allen key to remove the screws holding the safety caps in place. Remove the caps and replace the screws.
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Step 3 Use a 6mm Allen key and a 13mm open wrench to loosely attach the BUC to the DISH ASSEMBLY with M8 fasteners. Attention: Make sure the spring washers and flat washers are correctly positioned.
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Step 4 Tighten the nuts and screws. Attention: The distance between the BUC and the DISH ASSEMBLY should not exceed 3mm.
Step 5 Connect the cables to the BUC connectors. Use an SMA torque wrench for the SMA connectors.
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Post-Installation System Verification After replacing the BUC, power up the system and drive the BUC to 1dB compression (see the
AL-7103 MKII Installation and Operation Manual for instructions). Verify that the EB/N0 is
exactly as defined in the link budget.
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6. Load the new MTSLINK file from the memory stick. 7. When the file is fully loaded, reboot the CCU, either by activating the Reboot command from the ThisHost menu, or by powering off.
Follow steps 4-9 below and read the CPU Kind from the Connect ACU message box.
2. When you receive the zipped executable file, transfer it to a USB memory stick. 3. Connect the memory stick to the USB port in the CCU front panel. 4. In the MtsLink window, open the Host menu and select Communication. The Host Communication dialog box opens.
5. Click the TCP/IP tab. The SBC IP address appears in the Remote Address field. Make a note of the address. 6. Minimize the MtsLink window and activate the MTSDOCK program.
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7. Open the ACU menu on the MtsDock Menu Bar and select Connect. The Connect to ACU dialog box appears.
8. Verify that the IP address in the Network Address field matches the IP address that you noted from the MTSLINK application. If necessary, correct the address accordingly. 9. Click OK (Enter). When the connection is established between the CCU and the SBC, a message box appears confirming the connection, and displaying the CPU Kind.
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11. Load the new VXWORKS file from the memory stick. 12. When the file is fully loaded, reboot the SBC by selecting Reboot from the ACU menu. 13. When communication is reestablished between the SBC and the CCU, close the MTSDOCK application, and maximize MTSLINK. 14. Click the Version command on the MtsLink Menu Bar and verify that the new version was successfully installed and matches the software version used by the CCU.
If the CCU software version does not match the new SBC version, see Updating the CCU MtsLink Application on page 71.
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To update the IMU calibration file: 1. Activate the MTSDOCK application. 2. Open the ACU menu and select Connect. The Connect to ACU dialog box appears.
3. Verify that the correct SBC IP address appears in the Network Address field and click OK (Enter). When the connection is established between the CCU and the SBC, a message box appears confirming the connection. 4. Do one of the following:
If you are replacing the SBC, open the ACU menu, select Calibration, then Get IMU Calibration and save the IMU calibration file. Replace the SBC (see Replacing the SBC on page 9).
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If you are replacing the IMU, insert the Orbit memory stick with the calibration file into the front panel of the CCU.
5. Open the ACU menu and select Calibration, then Put IMU Calibration. 6. Reboot the SBC by selecting Reboot from the ACU menu.
If you wish to keep the existing system configuration, perform the following steps to download the configuration file from the current SBC before removal.
If you wish to load a new configuration file, replace the SBC and proceed to Step 6 (see Replacing the SBC on page 9).
2. Activate the MTSDOCK application. 3. Open the ACU menu and select Connect. The Connect to ACU dialog box appears.
4. Verify that the correct SBC IP address appears in the Network Address field and click OK (Enter). When the connection is established between the CCU and the SBC, a message box appears confirming the connection. 5. Open the ACU menu and select Get Configuration and save the configuration file.
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Replace the SBC (see Replacing the SBC on page 9). 6. Open the ACU menu and select Put Configuration. 7. Reboot the SBC by selecting Reboot from the ACU menu.
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4 Troubleshooting
The following chapter contains flow charts illustrating the chain of operations to perform when solving a variety of common problems encountered during system operation. The following troubleshooting procedures are described: Tracking Error Exceeds Limit Tracking Instability Pointing to Satellite Issues No Communication Between ADE and BDE The SBC Does Not Boot Wrong IP Address for SBC Blank CCU Screen The CCU Does Not Boot No GPS Output from the CCU No GPS Position Update GPS Communication Failed Compass Communication Failed Axis Jamming Errors Polarization Axis Jamming Error Axis Encoder Errors No Rx Lock No Tx Lock Missing System Files ADE / BDE Software Mismatch An additional section describes the System Status Dump command, which generates an ASCII file containing the system parameters defined during the commissioning process as well as system status indications.
Footnotes provide the MTSLINK path to commands required during the various troubleshooting procedures.
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* InConfig > Step-Track > Ku-Band ** InConfig > Receiver ** InConfig > Compass NMEA
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* InConfig > Step-Track > Ku-Band ** InConfig > Receiver ** InConfig > Compass NMEA
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84
85
86
87
88
89
90
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4.16 No Rx Lock
* InConfig > Receiver ** If the tracking and download frequencies are not the same, skip to the next step (modem settings).
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4.17 No Tx Lock
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* Maintenance Screen > BUC Status window ** Maintenance Screen > Tx Chain window *** 4W BUC 36dBm; 8W BUC 39dBm; 16W BUC 42dBm
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4.20.1
From the Operation Screen, open the Host menu and select Status Dump. A browser window opens, in which you can indicate where to save the file using the Save As command. You can save the report to the CCU desktop or directly to a disk-on-key.
4.20.2
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VxWorks Software Version: 4.6 6.08.2009 Work Time: SBC IP address: SBC Subnet Mask: SBC Default Gateway: 1 days 6 hours 203.88.94.2 255.255.255.240 203.88.94.1
Hardware ID *********** ---TYPE---Receiver: I/O: IMU: BUC: ---EPLD Version--Receiver: I/0: I/0: ---Serial Number--SBC: BUC: 1067 0068 DE12 DE12 DE12 29_0001 29-0001 SLDSTATE 8W Ku KoSpace M&C
---Calibration Files ID--imusave: nbrsave: nbralcsv: bucltab: 1301 4209093 4209093 REV D
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System Status ************* Operating Mode: IMU status: IRD: PolSw: Polariz: StepTrack Locked Locked 90 deg A:VL-RC
Ship Coordinates **************** Latitude: Longitude: Compass: 35.052 deg 129.001 deg 171.860 deg
Axes Offsets ************ --Encoder-Pedestal-X: Pedestal-Y: Pedestal-Z: -171.510 deg 38.950 deg 8.960 deg
Target
Position
******************************** 121.600 deg 29.206 deg -44.190 deg 122.823 deg 29.121 deg 91.432 deg
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Tracking Signal *************** AGC: Thresh: Tracking Frequency: -68.24 dBm -80.00 dBm 1250.725 3.42 Volts
Compass Setup ************* On Host: Compass Type: Compass Offset: YES NMEA_0183 -100.400 deg
Power State Readout ******************* Parameter --------+5V: 2.5V: 3.3V: +12V: -12V: +30V: LNBV: T(degC): 13.813 50.500 22.667 22.310 CPU SBC IMU SDU NBR
------------------------------------------------------5.029 2.485 3.319 11.782 -11.780 15.779 0.230 36.712 4.992 5.732
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Antenna Blockage **************** Angle ----------------Zone 0 Azimuth: Zone 0 Elevation: Zone 1 Azimuth: Zone 1 Elevation: Zone 2 Azimuth: Zone 2 Elevation: Zone 3 Azimuth: Zone 3 Elevation: From To
----------------------240.000 deg 0.000 deg 260.000 deg 0.000 deg 0.000 deg 0.000 deg 0.000 deg 0.000 deg 260.000 deg 40.000 deg 360.000 deg 10.000 deg 10.000 deg 5.000 deg 0.000 deg 0.000 deg
CCU's Information ***************** Version: Work Time: Communication Type: Remote Address: 4.6 6.08.2009 1 minutes 39 seconds TCP/IP 203.88.94.2
Compass Interface Setup *********************** Input Enable: COM Port Number: Baudrate: Format: NO 1 9600 8_NON_1
GPS Interface Setup ******************* Output Enable: COM Port Number: Baudrate: Format: NO 1 4800 8_NON_1
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GP GLL 1.000
System Massage Log ****************** Time Transition -------01-Jan-01 00:23:49 On\Off 01-Jan-01 00:23:48 Off/On 01-Jan-01 00:23:24 On\Off 01-Jan-01 00:18:54 Off/On 01-Jan-01 00:18:28 On\Off 01-Jan-01 00:18:27 Off/On 01-Jan-01 00:18:03 On\Off 01-Jan-01 00:13:08 On\Off 01-Jan-01 00:13:07 Off/On 01-Jan-01 00:11:58 Off/On 01-Jan-01 00:11:39 On\Off 01-Jan-01 00:11:37 Off/On Type ------Warning Warning Warning Warning Warning Warning Warning Warning Warning Warning Message Message ID Text
--- -----------------------002 Compass Communication Failed 002 Compass Communication Failed 180 No Noise Floor Table 180 No Noise Floor Table 002 Compass Communication Failed 002 Compass Communication Failed 180 No Noise Floor Table 002 Compass Communication Failed 002 Compass Communication Failed 180 No Noise Floor Table 018 Acquiring a Satellite 018 Acquiring a Satellite
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01-Jan-01 00:10:47 On\Off 01-Jan-01 00:10:45 Off/On 01-Jan-01 00:09:55 On\Off 01-Jan-01 00:09:53
018 Acquiring a Satellite 018 Acquiring a Satellite 018 Acquiring a Satellite 018 Acquiring a Satellite
********************************************
* Vessel Name:
________________________________
* Service Location:
________________________________
* Contact Number:
________________________________
* E-Mail Address:
________________________________
* Other Notes:
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
********************************************************************
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5 Preventive Maintenance
5.1 Introduction
The preventive maintenance program is designed to ensure that the OrSatTM AL-7103 system continues to function smoothly with maximum performance over time. The preventive maintenance program consists of a general health check to be performed once every year. This procedure should require one day to complete.
The health check should only be performed by a certified Orbit technician, who TM was trained on the OrSat AL-7103 system, and is familiar with the system and its utilities (e.g. Logger, Spectrum Analyzer, MTSDOCK).
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Check the serial number of the BUC, located on the BUC chassis, and compare it with the number that appears in the Hardware ID dialog box.
Pedestal X Position Feedback Pedestal X Position Error Pedestal X Velocity Feedback Pedestal X Velocity Output
2. In the Logger Configuration dialog box, set the sampling time to 6 ticks (60 seconds). 3. Return to the Maintenance Screen and select the Pedestal-X window. 4. Click the Open button and select Axis Config. The Pedestal-X dialog box appears.
5. Verify that the Test Trajectory parameters are assigned the following values:
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6. Close the Pedestal-X dialog box and click the Mode button. 7. Select Test Traj and wait for 10 seconds. 8. Enter the Logger screen and begin recording. Results should appear after 60 seconds.
Position/Feedback: The green wave shows the position of the selected axis in degrees. Data is usually sampled between -60 and +60, and should appear as a smooth sine wave. The velocity (blue wave) should be 0 at the limit of movement, as the dish halts and changes direction.
Position/Error: The red wave shows the backlash error of the gearbox. This line should be level on the 0 position of the graph, should be repeatable at maximum velocity, and should not show any extremely high or sharp peaks, which would indicate obstruction of movement.
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Velocity/Feedback: The blue wave shows the velocity of the selected axis in degrees per second. This data should appear as a smooth sign wave, with the highest velocity when Position/Feedback is in the 0 position. Velocity should be at 0 when the position feedback is at its highest or lowest position, according to the following formula:
V = A = 2 A T
deg/sec
Velocity/Output: The purple wave shows the current draw as a percentage for the motor. The higher the current draw, the more force is necessary to move the axis. Consequently, the lower the output value, the better for the system. Output should not exceed 40% in most cases; otherwise, power consumption is too high, and presents a definite pattern loosely following the Velocity/Feedback wave.
10. Save all results to a file named PX1 in the Mesr7200 sub-directory of the backup folder. 11. Return to the Pedestal-X window in the Maintenance Screen, click the Mode button and select Halt to stop the axis. 12. Repeat the above process for Period values of 60 and 10, saving the results in files
If any of the above tests do not pass, please contact the Orbit SatCom Service Center at support@orbit.com.
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5.2.4
1. Receive the link budget from the NOC. 2. Set the modem to drive the BUC to 1dB compression (see the OrSatTM AL-7103
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