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Field Service Procedure – Replacement Level Cage Kit, 2406

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Document No

137303 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levelcageassemblyonthe2406antenna.

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

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

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

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

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Ifanyofthesestepsfail,ortheACUreportsmodel“xx03”,theantennasN0parameterneedscalibratingandverifiedit

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

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Field Service Procedure – Replacement Level Cage Kit, 2406

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Document No

137303 Rev A

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

consent of Sea Tel, Inc. 

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6. 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.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

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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.

Field Service Procedure – Replacement Level Cage Kit, 2406

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Document No

137303 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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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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,notingthatthesystempoints

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

mechanicalproblemsuchasthebeltskippingonthepulley,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crosslevelandelevation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cross

levelorelevation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. 

Field Service Procedure – Replacement Level Cage Kit, 2406

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Document No

137303 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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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(insidethePCU)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.

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Field Service Procedure – Replacement Level Cage Kit, 2406

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Document No

137303 Rev A

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

consent of Sea Tel, Inc. 



12. 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.

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

13.1. Tools.



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

#1PhillipsScrewdriver

½”Wrench/Spanner

13.2. Procedure.

Procedureforreplacingthelevelcageassembly,SeaTelkitpartnumber:137301(levelcageassemblypartnumber:

122937‐2)andtensioningthelevelcagebelt.



*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.

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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.

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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).



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14. 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.

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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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