Service manual

ManualsBrandsRESEARCH CONCEPTS ManualsComputer equipmentRC2000

RC2000 Service Manual Chapter 1 Introduction 1

Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.COM

Chapter 1 INTRODUCTION

1.1 The RC2000 Antenna Controller Family

The RC2000 antenna controller family consists of the RC2000A, RC2000B POLAR, RC2000B AZ/EL,

RC2000C POLAR, RC2000C AZ/EL and RC2000C EL/AZ dual axis antenna controllers. All of the

various models are designed to work with 36-volt actuators and pulse type position sensors.

The RC2000A is a general-purpose dual axis antenna controller without the capability to track inclined

orbit satellites. The RC2000A does have the ability to be controlled via an RS-422 serial interface. An

IBM PC program, referred to as AUTOPILOT, is available to control the RC2000A and Standard Agile

Omni satellite receivers. An optional daughter board, designated RC2KPOL, allows the RC2000A to

control a rotating feed powered by a 24 volt DC motor that employs a potentiometer for position

feedback.

The RC2000B antenna controllers will track inclined orbit satellites, but do not have the ability to be

controlled via the onboard RS-422 serial interface. The RC2000B POLAR antenna controller is

designed to work with polar mount antennas. Two types of polar mounts are supported, elevation track

and declination track. With the elevation track polar mount, the elevation (or latitude) angle

adjustment is motorized. For the declination track polar mount, the mount declination angle adjustment

is motorized. The RC2000B AZ/EL antenna controller is designed to work with elevation over azimuth

type mounts. The RC2000B does not support the RC2KPOL daughter board.

The RC2000C controllers combine the serial communication and rotating feed support (provided by the

optional RC2KPOL daughter board) capabilities of the RC2000A with the inclined orbit satellite tracking

capabilities of the RC2000B. The RC2000C POLAR supports polar mounts with motorized elevation or

declination adjustments. The RC2000C AZ/EL is designed to interface with antennas that employ

elevation over azimuth type mounts. The RC2000C EL works with azimuth over elevation mounts.

Here is a brief listing of the capabilities of the RC2000 family of antenna controllers:

1. The controller utilizes a solid-state drive system capable of providing 8 amps to the antenna

actuators. The drive system has built-in over-current sensing, with mechanical relay backup to

disconnect the drive from the actuators in the event of a fault. It is possible with the RC2000 to

control antennas not powered by 36 volt DC actuators. See the white paper entitled “Controlling

Antennas Powered by AC or Large DC Motors with the RC1000 or RC2000 Antenna Controllers.”

This paper can be obtained from our web site at: www.researchconcepts.com.

2. The controller can control polarization via a polarotor type interface. In addition, an AUTO-POL

feature allows the polarization to be controlled via a digital input or contact closure supplied by a

receiver to the antenna controller.

The controller also has an internal expansion port that can accept optional daughter boards. Two

daughter boards are available which can provide polarization control, designated RC2KPOL and

RC2KHPP. The RC2KPOL is designed for use with the Seavey model ESR-124D motorized feed

with potentiometer feedback. The Seavey feed requires 24 volts at 500 milliamps. The RC2KHPP

option is designed for motorized feeds with potentiometer feedback which require 5 to 40 volts DC

at currents up to 3 amps. Version 1.x0 of the RC2000A software supports the RC2KPOL option.

Version 1.x1 of the RC2000A software supports the RC2KHPP option. The RC2KPOL and the

RC2KHPP options are supported in only the RC2000A and RC2000C series. Contact the factory

for versions of the RC2000C software that supports the RC2KHPP.

3. Position sensing feedback can be supplied by any pulse-based sensor, reed switch, Hall effect, or

electro-optical. There is no need for special sensors or actuators. The RC2000 antenna controllers

keep track of both rising and falling pulse edges from the pulse sensor for increased accuracy.

4. In each of the RC2000 controllers, the non-volatile memory can hold position and polarization data

for numerous satellites. The RC2000A can accommodate 50 geostationary satellites. The

RC2000B can accommodate 50 satellites total…5 of which may be in an inclined orbit. The

RC2000C can hold data for 35 satellites total…4 of which may be in an inclined orbit.

Summary of content (39 pages)

PAGE 1
RC2000 Service Manual Chapter 1 Chapter 1 1.1 Introduction 1 INTRODUCTION The RC2000 Antenna Controller Family The RC2000 antenna controller family consists of the RC2000A, RC2000B POLAR, RC2000B AZ/EL, RC2000C POLAR, RC2000C AZ/EL and RC2000C EL/AZ dual axis antenna controllers. All of the various models are designed to work with 36-volt actuators and pulse type position sensors. The RC2000A is a general-purpose dual axis antenna controller without the capability to track inclined orbit satellites.
PAGE 2
RC2000 Service Manual Chapter 1 Introduction 2 5. The Adapti-Drive variable speed control system allows the user to specify the desired slow speed for each axis. The Adapti-Drive system will then adjust the actuator voltage (via a pulse width modulation scheme) to maintain the speed selected by the user. This alleviates the problem of poor speed regulation with varying direction along a given axis associated with constant voltage slow speed systems. 6.
PAGE 3
RC2000 Service Manual Chapter 1 Introduction 3 PROGRAM_TRACK mode the accuracy of the track table is monitored by periodically peaking up the receiver AGC signal. If the error exceeds a level set by the user, all entries in the track table are flagged for update. The period between these accuracy checks is specified by the user, and typically varies from once a day to once a week. SEARCH mode is entered from STEP_TRACK mode when the satellite signal has been lost.
PAGE 4
RC2000 Service Manual Chapter 1 Introduction 4 RC2KPOL: 20 volts DC at 500 milliamps (the RC2KPOL option requires software version 1.40) RC2KHPP: 5-40 volt DC output (output voltage set by potentiometer (P2) on the RC2KHPP board), 3 amps at 40 volts DC, 400 milliamps at 5 volts DC (the RC2KHPP option requires software version 1.41. C. NON-VOLATILE MEMORY BATTERY Duracell DL2450 D. AC INPUT AND DRIVE SUPPLY LINES These are protected by circuit breakers.
PAGE 5
RC2000 Service Manual Chapter 2 Chapter 2 2.1 Theory of Operation 5 THEORY OF OPERATION System Figure 2.1 (page 6) shows two views of the RC2000 chassis. Looking down on the controller from above shows the transformer mounted in the left third of the housing, the drive board in the center, and the digital board on the right. AC Power enter the housing through the back panel on the left. The LCD display and keypad are mounted on the front near the drive and digital boards respectively. Figure 2.
PAGE 6
RC2000 Service Manual Chapter 2 Theory of Operation 6 Figure 2.1 RC2000 Top and Front Views Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 7
RC2000 Service Manual Chapter 2 Theory of Operation 7 Figure 2.2 RC2000 Interconnection Diagram Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 8
RC2000 Service Manual Chapter 2 Theory of Operation 8 The 6264LP is an 8K x 8 low power static RAM (U5) with battery backup provided by circuitry on the digital board. The static RAM uses 2 chip selects. CE2 is an active high chip select which is produced by U2. /CE1 is an active low chip select produced by U7. /CE1 insures that if a powerdown occurs during a write cycle the contents of the static RAM will not be corrupted.
PAGE 9
RC2000 Service Manual Chapter 2 Theory of Operation 9 Figure 2.3 Digital Board Layout Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 10
RC2000 Service Manual Chapter 2 Theory of Operation 10 Figure 2.4 Digital Board Schematic Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 11
RC2000 Service Manual Theory of Operation 11 Chapter 2 MODESEL2, MODESEL1, MODESEL0 ... these signals are generated by the micro-controller. These signals are the commands for the state machine. Here are the various commands which may be present on these lines ... BRAKE (000) ... the two lower MOSFETs of the bridge are on. This mode is used to stop the motors by means of dynamic braking. IDLE (001) ... all MOSFETs off. This state is active when an alarm is detected. SLOW MOVEMENT EAST or DOWN (010) ...
PAGE 12
RC2000 Service Manual 2.2.7 Theory of Operation 12 Chapter 2 Signal Strength Input Circuits The RC2000 accepts 2 analog voltages proportional to received signal strength. The controller will use the strongest signal. The signal strength inputs are normally connected to the AGC (automatic gain control) output of a satellite receiver. Each channel has an offset and gain adjustment.
PAGE 13
RC2000 Service Manual Quantity Theory of Operation 13 Chapter 2 Type Value Ref. Designators 7 CAP 4.7T C1,C14,C26,C28,C3,C4,C5 21 CAP .1 C10,C11,C12,C13,C15,C16,C17,C18,C19,C2,C20, C25,C27,C31,C32,C34,C35,C43,C6,C7,C8 4 CAP 100p C21,C22,C23,C24 1 CAP 470uF C30 1 CAP 10 C33 2 CAP 30p C38,C39 2 CAP .039 C40,C41 2 CAP 4.
PAGE 14
RC2000 Service Manual Quantity Theory of Operation 14 Chapter 2 Type Value Ref. Designators 2 POT 2K P3,P5 1 REF02H REF02H U17 3 RES 100 R10,R18,R29 2 RES 220 R11,R19 6 RES 470 R12,R20,R26,R28,R39,R44 7 RES 1K R13,R15,R16,R21,R23,R24,R9 2 RES 5.1K R14,R22 3 RES 1OOK R17,R25,R38 5 RES 1M R27,R35,R40,R45,R46 1 RES 240 R30 1 RES 33 R31 1 RES 6.8 R34 2 RES 20K R36,R37 1 RES 10M R4 2 RES 10K R41,R42 1 RES 430K R43 1 RES 8.2M R5 1 RES 7.
PAGE 15
RC2000 Service Manual Quantity Chapter 2 Type Value Theory of Operation 15 Ref. Designators 1 TMOSN BS170 Q1 1 TRANZORB P6KE6.8 D12 1 VOLTREG LM140-5 VR2 1 ZORB P6KE6.8 D6 Total Parts: 147 2.3 Drive Board The motor drive board, located in the center of the RC2000 chassis, contains the circuitry which converts the AC power from the drive winding of the transformer to DC and, using solid-state devices, switches this DC power across the motor drive lines.
PAGE 16
RC2000 Service Manual Theory of Operation 16 Chapter 2 Figure 2.5 Drive Board Layout Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 17
RC2000 Service Manual Chapter 2 Theory of Operation 17 Figure 2.6 Drive Board Schematic Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 18
RC2000 Service Manual 2.3.4 Chapter 2 Theory of Operation 18 FET H-bridge The DC drive signal is connected across the motor lines through the use of a solid-state switch configuration known as an “H-bridge.” This name arises due to the switch elements being located on the four vertical sections of an “H” and the motor located in the center section of the “H.
PAGE 19
RC2000 Service Manual Theory of Operation 19 Chapter 2 Drive Polarity on J2 output terminals Command Azimuth FETs Elevation FETs AZ1 AZ2 EL1 EL2 AZ_East Q1=off,Q2=on,Q3=on,Q4=off Q5=na,Q6=na,Q7=na,Q8=na +V 0V 0V 0V AZ_West Q1=on,Q2=off,Q3=off,Q4=on Q5=na,Q6=na,Q7=na,G8=na 0V V+ 0V 0V EL_Up Q1=na,Q2=na,Q3=na,Q4=na Q5=on,Q6=off,Q7=off,Q8=on 0V 0V 0V V+ EL_Down Q1=na,Q2=na,Q3=na,Q4=na Q5=off,Q6=on,Q7=on,Q8=off 0V 0V V+ 0V “Brake” Mode Q1=off,Q2=off,Q3=on,Q4=on Q5=off,Q6=o
PAGE 20
RC2000 Service Manual Quantity Theory of Operation 20 Chapter 2 Type Value Ref. Designators 1 POLCAP 3300uF/63V C2 2 POT 50K P1,P2 2 RELAY-SPST T90S1D12-24 K1,K2 8 RES 3.6K R1,R10,R2,R28,R29,R36,R37,R9 1 RES 3.6K,.5W R11 2 RES 390,1W R12,R13 8 RES 1.1K,1% R14,R15,R18,R19,R21,R22,R25,R26 4 RES 475,1% R16,R20,R23,R27 2 RES .05 R17,R24 5 RES 7.
PAGE 21
RC2000 Service Manual Chapter 3 Chapter 3 Acceptance Test Procedure 21 ACCEPTANCE TEST PROCEDURE This test procedure is followed by test personnel at the factory. 1. Turn on test bench power supplies and voltmeters. Install EPROM, EPLD, and clock devices as specified for the particular model being tested. Verify the orientations of all installed ICs. 2. Place the input voltage switch of the 2000 into the 115V position. Plug in the unit. 3.
PAGE 22
RC2000 Service Manual Chapter 3 Acceptance Test Procedure 22 read thirty. Set the west limit by pressing the “W” key and verifying that the AZ count value is increasing. Then press 7 to set the west limit. Hit the BKSPC key to confirm the limits setting. 16. Set the down limit by pressing the “S” key and verifying that the EL count value is decreasing. Then press 9 to set the down limit. The EL count should now read 30.
PAGE 23
RC2000 Service Manual Chapter 4 4.1 Chapter 4 Common RC2000 Questions 23 COMMON RC2000 QUESTIONS Invalid Data Entry This error can occur in AUTO mode when the user attempts to position the antenna on a satellite which has been previously stored in non-volatile memory (satellites are stored in non-volatile memory via SETUP mode) and either the azimuth, elevation, horizontal polarization or vertical polarization data fields contain invalid data.
PAGE 24
RC2000 Service Manual Chapter 4 Common RC2000 Questions 24 1. A servo type polarization control device based on the Chaparral polarotor. The polarotor has a three wire interface (5 volts DC, Pulse, and Return). The controller positions the polarotor by sending a pulse width modulated (pwm) waveform to the polarotor. The off time of the waveform is fixed at 15 to 20 milliseconds (msec) and the on time varies between 0.8 msec and 2.2 msec.
PAGE 25
RC2000 Service Manual 4.1.6 Chapter 4 Common RC2000 Questions 25 No Polarization Control Device Attached to the RC2000 If there is no polarization control device used with the RC2000 the controller should be configured for polarotor operation. This is done by setting the Rotating Feed Present CONFIG mode item to 0 (No). When storing a satellite in memory (via SETUP mode) make sure that the current polarization position (displayed to the right of the POL: or PL: banners) is not at the CW or CCW limit.
PAGE 26
RC2000 Service Manual Chapter 4 Common RC2000 Questions 26 active - anytime a pulse is received it increments or decrements the position count based on the direction the antenna was last commanded to move. If a position pulse is received by the controller and the controller is not either moving or in a coast period defined by the Az/El Fast/Slow Deadbands described above a RUNAWAY error will occur.
PAGE 27
RC2000 Service Manual Chapter 4 Common RC2000 Questions 27 The limit error occurs when the antenna controller is tracking an inclined orbit satellite and one of the antenna azimuth or elevation limits is reached. For the RC2000B models this can occur either when then controller is in the Search sub-mode performing a search or when the antenna is being peaked in either the Step Track or Program Track sub-modes.
PAGE 28
RC2000 Service Manual Chapter 4 Common RC2000 Questions 28 satellite is passing through the earth's equatorial plane). A peakup will be triggered when the time since the last peakup equals a value that corresponds to a pointing error of Max Track Error dB at the maximum angular velocity of the satellite as seen by the antenna. The Max Track Error is specified via CONFIG mode.
PAGE 29
RC2000 Service Manual 4.7 Chapter 4 Common RC2000 Questions 29 DH Gibralter Mounts The DH antenna uses a chain drive for the azimuth axis. There is not much resolution on that axis (800 counts per radian for azimuth versus 2600 counts per radian for elevation). The DH antenna is equipped with a chain tension adjustment on one end of the chain. This adjustment is a threaded rod which tightens up the chain.
PAGE 30
RC2000 Service Manual Chapter 4 Common RC2000 Questions 30 The AGC input circuit consists of a voltage divider implemented with a 2.4 and 1 Meg ohm resistors followed by an op amp voltage follower (see Figure X). The maximum common mode input voltage of the op amp is approximately 3 volts (worst case). If the input to the voltage divider exceeds 10.2 volts. the voltage at the input of the op amp will exceed the common mode voltage.
PAGE 31
RC2000 Service Manual Chapter 5 5.1 Chapter 5 Upgrading the RC2000 31 UPGRADING THE RC2000 Updating RC2000 and Nomad Model Antenna Controllers This paper describes the procedure for upgrading the software (contained in an EPROM memory chip) of early model RC2000A (Nomad I), RC2000B (Nomad II), and RC2000C antenna controllers. Early versions of these controllers contain 64k x 8 static RAM (SRAM) chips. Current versions of these controllers contain 8k x 8 SRAM chips.
PAGE 32
RC2000 Service Manual Chapter 5 Upgrading the RC2000 32 7. Go to LIMITS mode. WITHOUT MOVING THE ANTENNA set the down and east limits. AFTER THE EAST AND DOWN LIMITS HAVE BEEN SET, jog the antenna to the positions for the west and up limit recorded in step 1. Set the west and up limits. After the west and up limits have been set, exit LIMITS mode by hitting the MODE KEY. 8. Go to CONFIG mode and key in the data recorded in step 2 above. Each entry must be terminated with the ENTER KEY.
PAGE 33
RC2000 Service Manual Chapter 6 6.1 Chapter 6 Using the RS232-RS422 Protocol Converter 33 USING THE RS232-RS422 PROTOCOL CONVERTER RC1KADP RS232 to RS422 Protocol Converter The serial port on RC1000A and RC2000 antenna controllers uses RS422 signal levels. This allows the antenna controllers to be connected in a daisy chain fashion (i.e. a single PC equipped with a single RS422 output port can communicate with many antenna controllers).
PAGE 34
RC2000 Service Manual Chapter 6 Using the RS232-RS422 Protocol Converter 34 Figure 6.1…Interconnect Diagram for Omni 830BR and RC2000 an a single serial connection Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 35
RC2000 Service Manual Chapter 6 Using the RS232-RS422 Protocol Converter 35 Figure 6.2…Schematic Diagram for the RC1KADP Research Concepts, Inc; 10679 Widmer; Lenexa, Kansas; USA 66215 WWW.RESEARCHCONCEPTS.
PAGE 36
RC2000 Service Manual Chapter 6 Using the RS232-RS422 Protocol Converter 36 6.3 Alternate Test Procedure for the RC1KADP 6.3.1 Test Procedure for RS485A1 Board (RC1KADP) 1. Clip lead TX1 to RX1 on terminal output strip 2. Clip lead TX2 to RX2 on terminal output strip. 3. Connect ground lead to power supply ground and voltmeter ground, then apply to pin on input terminal strip. 4. Apply 9V/200mA to J3 jack. 5.
PAGE 37
TABLE OF CONTENTS CHAPTER 1 1.1 1.2 1.3 1.4 INTRODUCTION The RC2000 Antenna Controller Family Tracking Inclined Orbit Satellites RC2000B/C Tracking Algorithm Specifications CHAPTER 2 THEORY OF OPERATION 2.1 2.2 System Digital Board 2.2.1 8097BH Micro-Controller and Support Peripherals 2.2.2 Keypad 2.2.3 LCD Display 2.2.4 Motor Control Circuitry 2.2.5 Description of the signals which control the state machine and which are generated by the state machine 2.2.6 Pulse Position Sensors 2.2.
PAGE 38
REVISION HISTORY 1.15.96 * v1.00 First issuance 3.27.96 * v1.10 Added ADP, Large Motor, DH Gibralter, and AGC input information. 11.16.98 * v1.
PAGE 39
RC2000 Service Manual v 1.11 RESEARCH CONCEPTS, INC.