General Dynamics 7200 Operation And Maintenance Manual

the disclosure of this

U.S. persons, or the

U.S. government approvals.

CG-1280

REV N

AUGUST 2013

OPERATION AND MAINTENANCE MANUAL

FOR THE

7200 ANTENNA CONTROL SYSTEM

EXPORT CONTROL WARNING -

document or its contents to non­transmission of its contents outside the United States must
be in compliance with U.S. Export Laws and Regulations.
The bearer of this document is under obligation to know the
applicable restrictions for the dissemination of its contents
that relate to U.S. Export Laws and Regulations or any other

3750 W. Loop 281

Longview, Texas 75604

N- Revised table 5-35

L. Shirey

8/2/13

D. Harrison

8/2/13

13463

M – Revised Analog Input Conn

D. Cunningham

3/15/12

D. Harrison

3/15/12

11420

L – Revised for CE Certification

B. Tanner

11/15/11

S. Martinez

11/15/11

10897

K – Table 5-28 Corrections

B. Tanner

8/13/10

D. Harrison

8/13/10

10029

J – NORAD Tracking Appx. K

B. Tanner

5/11/09

W. Black

5/11/09

8676

H – V1000 Updates

B. Tanner

3-23-09

L. Bustamante

3-23-09

8559

G – Appendix J

A. Weaver

5-5-08

K. Kaufman

5-5-2008

7895

F – Encoders, misc

M. Neely

4-25-07

J. Upatham

4-25-007

6540

E – OE Tracking, params

M. Neely

1-12-05

D. Bulgrien

1-12-05

5567

D – parameters corrected

M. Neely

1-04-05

D. Bulgrien

1-04-05

5566

D – Set 0 and -3 dB, amnd

M. Neely

7-21-04

B. Harris

7-21-04

5353

D – Trblshtg. App. updated

M. Neely

6-7-04

D. Harrison

6-7-04

5272

D – ACU Sync added

M. Neely

4-23-04

M. Neibert

4-23-04

5127

C – Numerous updates

M. Neely

10-13-03

D. Harding

10-13-03

4769

B – V4 Software Rewrite

M. Neely

5-16-03

D. Harding

5-16-03

4621

A – First release

M. Neely

2-18-03

D. Harding

2-18-03

4554

Rev. No/change

Revised By

Date

Approved By

Date

ECO#

Revision History

NOTICES

WARNING

THE ELECTRICAL CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS. PERSONNEL
MUST OBSERVE SAFETY REGULATIONS AT ALL TIMES.

This manual is intended as a general guide for trained and qualified personnel who are aware of the
dangers of handling potentially hazardous electrical and electronic circuits. This manual is not intended
to contain a complete statement of all safety precautions that should be observed by personnel in
using this or other electronic equipment.

WARNING

IN CASE OF EMERGENCY BE SURE THAT POWER IS DISCONNECTED.

The manufacturer has attempted to detail in this manual all areas of possible danger to personnel in
connection with the use of this equipment. Personnel should use caution when installing, operating,
and servicing this equipment. Care should be taken to avoid electrical shock, whether the hazard is
caused by design or malfunction.

WARNING

ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, ENCLOSURES, PANELS, OR SHIELDS.
ALWAYS USE GROUNDING STICKS AND SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING.
NEVER MAKE INTERNAL ADJUSTMENTS OR PERFORM MAINTENANCE OR SERVICE WHEN ALONE
OR FATIGUED.

The manufacturer is specifically not liable for any damage or injury arising from improper procedures
or failure to follow the instructions contained in this manual or failure to exercise due care and caution
in the installation, operation, and service of this equipment or use by improperly trained or
inexperienced personnel performing such tasks. During installation and operation of this equipment,
local building codes and fire protection standards must be observed.

All computer software, technical data, or other information pertaining to the equipment covered by this
manual is proprietary to General Dynamics. Such information is transmitted in this manual or related
documents for the benefit of General Dynamics customers and is not to be disclosed to other parties
verbally or in writing without prior written approval of General Dynamics. Additionally, this manual
may not be reproduced in whole or in part without written consent from General Dynamics.

© 2011 General Dynamics SATCOM Technologies

PROPRIETARY NOTICE

72/23/EEC

The Low Voltage Directive

and its amending directives.

89/336/EEC

The Electromagnetic Compatibility Directive

and its amending directives.

EN 61010-1: 2001

EN 300339: 1998

EN 55022: 1998

Class B

EN 61000-4-2: 1995

(4/8kV)

EN 61000-4-3: 1995

(3V/m)

EN 61000-4-4: 1995

(2kV/1kV)

EN 61000-4-5: 1995

(2/1kV)

EN 61000-4-6: 1996

(3 Vrms)

EN 61000-4-11: 1994

>95%-0.5p, 30%-25p,>95%-250p

Signed:

Date:

February 18, 2003

Declaration of Conformit y

The General Dynamics 7200 ACU Rack Mount Unit (201379)

was tested to the follow in g specific ati ons an d fou nd to be in c omplianc e

with the require d c r ite ria on th e in d ica ted test date.

In accordance with the following directives:

It has been designed and manuf acture d to the fo ll o wing specif ica tio ns:

I hereby declare that the equipment named above, when installed according to manufacturer’s

instructions, complies wi t h the ab ove d irecti ves a nd standar d s.

General Dynamics SATCOM Technologies

Telephone: [phone] Fax: [phone]

3750 W. Loop 281

Longview, TX 75604

Table of Contents

TABLE OF CONTENTS

1.0 INTRODUCTION ....................................................................................... 1

1.1 Purpose .......................................................................................... 1

1.2 Scope ............................................................................................ 1

1.3 Organization of Included Contents ..................................................... 1

1.4 Supplemental Literature on CD and Website ....................................... 2

1.4 Technical Support ........................................................................... 3

1.5 Important Safety Information ............................................................ 3

1.5.1 Explanation of Safety Symbols ................................................................ 3

1.5.2 Technical & Environmental Specifications ................................................. 3

1.5.3 User Supplied Power Cord Requirements................................................... 3

1.5.4 Note about connecting/disconnect from mains power. ................................ 4

2.0 OVERVIEW OF THE 7200 ACS ................................................................ 1

2.1 General Information About the 7200 ACS .......................................... 1

2.2 System Specifications ...................................................................... 2

2.3 System Configuration ...................................................................... 3

FIGURE 2-1 TYPICAL 7200 ACS BLOCK DIAGRAM ...................... 3

2.4 System Hardware ............................................................................ 5

2.4.1 7200 ACU Hardware ............................................................................. 6

FIGURE 2-2 7200 ANTENNA CONTROL UNIT FRONT PANEL ........ 6

FIGURE 2-3 7200 ACU FUNCTIONAL BLOCK DIAGRAM ............... 7

FIGURE 2-4 7200 ANTENNA CONTROL UNIT TOP VIEW .............. 8

FIGURE 2-5 7200 ANTENNA CONTROL UNIT SIDE VIEW ............. 8

FIGURE 2-6 VCPU CARD ........................................................... 9

2.4.2 Antenna Drive Cabinet Hardware ........................................................... 16

FIGURE 2-7 DRIVE CABINET BLOCK DIAGRAM ......................... 17

FIGURE 2-8 DRIVE CABINET ASSEMBLY ................................... 18

2.5 Controls and Indicators .................................................................. 21

2.5.1 7200 ACU Controls and Indicators ......................................................... 21

FIGURE 2-9 7200 ANTENNA CONTROL UNIT DISPLAY .............. 22

2.5.2 Drive Cabinet Controls and Indicators ..................................................... 25

2.6 System Functions .......................................................................... 26

2.7 Standby ....................................................................................... 26

2.8 Manual Control Via Portable Maintenance Control Unit (PMCU) .......... 27

FIGURE 2-10 PORTABLE MAINTENANCE CONTROL UNITS .......... 27

2.8.1 Manual Antenna Control from the Drive Cabinet ...................................... 28

2.8.2 Manual Antenna Control from the Antenna Control Unit ............................ 28

2.9 Immediate Tracking ....................................................................... 28

i

Table of Contents

Move to Longitude ............................................................................... 28

2.9.1

2.9.2 Move to Look Angles ........................................................................... 28

2.9.3 Steptrack ........................................................................................... 29

2.9.4 Star Tracking ...................................................................................... 29

2.9.5 Intelsat 11-element Track ..................................................................... 29

2.9.6 Orbital Element Track (Optional) ............................................................ 30

2.10 Tracking Functions ....................................................................... 31

2.10.1 Orbit Prediction Tracking ...................................................................... 31

3.0 THEORY ................................................................................................ 1

3.1 OPT ............................................................................................... 1

3.1.1 Orbit Prediction ..................................................................................... 1

3.1.2 Orbit Determination ............................................................................... 2

3.2 Orbit Scan ...................................................................................... 3

3.2.1 Orbit Scan Theory ................................................................................. 3

FIGURE 3-1 ORBIT SCAN THEORY ............................................. 4

3.2.2 Orbit Scan Operation.............................................................................. 4

4.0 INSTALLATION AND INITIAL SETUP OF SYSTEM ...................................... 1

4.1 Overview ....................................................................................... 1

4.2 Mechanical Installation ..................................................................... 1

4.2.1 Antenna-Mounted Components ............................................................... 1

4.2.2 Installing the Drive Cabinet ..................................................................... 1

4.2.3 Installing the 7200 ACU ......................................................................... 2

FIGURE 4-1 MOUNTING THE 7200 ACU ..................................... 2

4.3 System Cabling ............................................................................... 4

FIGURE 4-2 7200 ANTENNA CONTROL SYSTEM CABLING
DIAGRAM 4

4.3.1 Drive Cabinet Main Power Connection ...................................................... 5

FIGURE 4-3 DRIVE CABINET ASSEMBLY ..................................... 5

4.3.2 Connecting the Drive Motors to the Drive Cabinet ...................................... 6

4.3.3 Limit Switch Connections ....................................................................... 7

4.3.4 Installing the 7200 ACU Control Cable ..................................................... 8

FIGURE 4-4 7200 ANTENNA CONTROL UNIT REAR PANEL .......... 8

4.3.5 Resolver and Encoder Connections ......................................................... 11

4.3.6 Analog Input Connections ..................................................................... 16

4.3.7 Digital Inputs ...................................................................................... 17

4.3.8 Remote Communications Connections .................................................... 18

4.3.9 Remote Beacon Select and Summary Fault Connections ........................... 20

4.4 Initial Power-Up and System Setup .................................................. 21

4.4.1 Drive Cabinet Power-Up and Initialization ................................................ 22

FIGURE 4-5 GPD315 DIGITAL OPERATOR INDICATOR AND KEY
DESCRIPTION 23

FIGURE 4-6 DIGITAL OPERATOR INDICATOR AND KEY
DESCRIPTION 24

FIGURE 4-7 V1000 KEYS, DISPLAYS, AND LEDS ...................... 25

ii

Table of Contents

FIGURE 4-8 V1000 DIGITAL LED OPERATOR SCREEN STRUCTURE
26

FIGURE 4-9 V1000 DRIVE PARAMETER SETTINGS OR VALUES .. 27

4.4.2 ACU Power-Up and Initialization ............................................................ 32

5.0 OPERATION ........................................................................................... 1

5.1 Introduction .................................................................................... 1

5.2 The 7200 ACS Menu System ........................................................... 1

FIGURE 5-1 7200 ACS BASIC MENU SYSTEM ............................ 2

5.2.1 Multiscreen Menus ................................................................................ 2

FIGURE 5-2 MULTISCREEN MENU .............................................. 2

5.2.2 Menu Items .......................................................................................... 3

FIGURE 5-3 TRACKING FUNCTIONS MENU SYSTEM ................... 3

5.3 The Help System ............................................................................. 3

FIGURE 5-4 ACS HELP SCREEN (PARAMETER HELP SCREEN) ....... 4

FIGURE 5-5 7200 ACS HELP SCREEN (INTRODUCTORY HELP) ..... 4

5.4 System Prompts .............................................................................. 5

FIGURE 5-6 PARAMETER EDIT SCREEN ...................................... 5

5.4.1 Error Messages for Incorrect Entries ......................................................... 5

5.4.2 Confirmation Messages .......................................................................... 6

5.5 Parameter and Data Storage ............................................................. 6

5.6 Power-Up Procedures ...................................................................... 6

5.7 Manual Movement of the Antenna .................................................... 7

5.7.1 Manual Movement From the Drive Cabinet (PMCU) .................................... 7

5.7.2 Manual Movement From the ACU ............................................................ 8

5.8 The 7200 ACS Main Menu ............................................................... 8

FIGURE 5-7 7200 ACU MAIN MENU SCREEN .............................. 8

5.8.1 Return to Standby (Stop Tracking) Function .............................................. 9

5.8.2 Tracking Functions Menu ........................................................................ 9

FIGURE 5-8 TRACK A TARGET SCREEN ................................... 10

FIGURE 5-9 MANUALLY BIAS TARGET SCREEN ........................ 11

FIGURE 5-10 MANUAL ANTENNA CONTROL SCREEN .................. 18

5.8.3 Clear/Correct System Faults Function ..................................................... 34

5.8.4 Set User Level (and Passwords) Menu .................................................... 36

5.8.5 Display System Status Menu ................................................................. 37

FIGURE 5-11 RDC STATES DISPLAY .......................................... 39

5.8.6 Edit System Configuration Menu ............................................................ 52

FIGURE 5-12 SOFT LIMITS ........................................................ 58

6.0 MAINTENANCE ...................................................................................... 1

iii

Table of Contents

6.1 Air Filter ......................................................................................... 1

FIGURE 6-1 7200 ACU REAR PANEL FAN ................................... 1

6.2 Battery ........................................................................................... 2

6.2.1 Checking the Battery.............................................................................. 2

6.2.2 Replacing the Battery ............................................................................. 2

6.3 Power Entry Module Fuse ................................................................. 2

7.0 ENGINEERING DRAWINGS ..................................................................... 1

APPENDIX A Acronyms and Abbreviations ..................................................... A-1

APPENDIX B 7200 ACU Password Protection ............................................... B-1

APPENDIX C Two Speed Resolver Calibration ................................................ C-1

APPENDIX D Tracking Tutorial for Operators .................................................. D-1

APPENDIX E 7200 Troubleshooting Guide ..................................................... E-1

APPENDIX F Site Acceptance Test Procedure .................................................F-1

APPENDIX G Graphical Menu Tree ................................................................ G-1

APPENDIX H Vendor Data ............................................................................ H-1

APPENDIX J Field Procedure to Install CTB055 ...............................................J-1

APPENDIX K NORAD Tracking ..................................................................... K-1

APPENDIX L Addendum Notes for CP/LP-PATH Option .................................... L-1

iv

Introduction

1.0 INTRODUCTION

1.1 Purpose

This manual provides the user with the information necessary to install and operate
the General Dynamics SATCOM Technologies (GDST) Model 7200 Antenna
Control System (ACS). Failure to follow the instructions and all cautions and
warnings provided in this manual may result in improper installation and/or
operation of the 7200 ACS.

1.2 Scope

This manual primarily contains the information related to the 7200 ACS, and
includes limited information about the antenna structure, the equipment used to
develop the tracking signal, and other equipment peripheral to the 7200 ACS.

1.3 Organization of Included Contents

This manual is divided into the following sections:

• Section 1.0, Introduction, gives the purpose, scope, and organization of this manual.

Information for obtaining technical support is also included in this section.

• Section

specifications, the functions of the system, and a description of the controls and indicators.

• Section

• Section

connections of system cabling and explaining the setup and initial power-up of the system.

• Section

ACS.

• Section

• Section

the drive cabinet.

• Appendix A, Acronyms and Abbreviations, lists the definitions of all acronyms and

abbreviations used in this manual.

• Appendix B, 7200 ACU Password Protection, provides information to set, change, and clear

user passwords from the 7200 ACS. It also provides information to disable password
protection on the system.

• Appendix C, Two-Speed Resolver Calibration, provides instructions for calibrating the two-

speed resolvers in the 7200 ACS.

2.0, Overview of the 7200 ACS, provides a general overview of the system, including

3.0, Theory of Operation, explains the theory of operation of the 7200 ACS.

4.0, Installation, provides instructions for installing the 7200 ACS, showing the

5.0, Operation, provides detailed information for configuring and operating the 7200

6.0, Maintenance, provides information necessary for maintaining the 7200.

7.0, Engineering Drawings, contains the engineering drawings for the 7200 ACU and

1-1

Introduction

• Appendix D, Tracking Tutorial for Operators, provides instructions for quickly setting up

tracking with the 7200 ACS, eliminating the need to read the step-by-step instructions in
Section 5.0 of the manual.

• Appendix E, 7200 Troubleshooting Guide, contains probable causes and corrective action for

troubleshooting the 7200 ACS.

• Appendix F, Site Acceptance Test Procedure, contains the final proof of acceptance procedure

for the antenna control system.

• Appendix G, Graphical Menu Tree, contains a graphical menu tree that depicts all menus and

parameters for the system.

1.4 Supplemental Literature on CD and Website

Related documentation that is highly specialized or infrequently used has been
included on an enclosed Compact Disc. This information is also maintained on the
General Dynamics SATCOM Technologies website at http://www.gdsatcom.com.

This manual and all its various appendices have also been included on the CD. In
addition, documentation for prior generation (legacy) systems is included.

TABLE 1-1 SUPPLEMENTAL DOCUMENTATION

Directory Contents

7200 O&M Manual

Protocol Documents

Firmware Upgrade Procedures

Factory Test Procedures Reports

7200 Legacy Product Documents

CG-1280 – All subdocuments

(Including vendor literature)

CG-6042 – RC M&C protocol document
CG-6045 – MT M&C protocol document
CG-6041 – GPIB protocol document

CG-1281 – VCPU Flash Firmware Upgrade

Procedure V4.x

CG-1295 – 72XX ACU Parameter Download/

Upload V4.3+

CG-0281 – Factory Test Proc. – 7200 (VCPU)
CG-0282 – Factory Test Report – 7200 (VCPU)
CG-0283 – Factory Test Proc. – VCPU
CG-0284 – Factory Test Report – VCPU

CG-1190 – 7200 w/7150 (NTAC 2000 Inverters)
CG-1210 – 7200 w/7134 (NTAC 2000 Inverters)
CG-1260 – 7200 w/7150 (GPD315 Inverters)

(non-VCPU 7200)

CG-5546 – Force CPU 30xxxx Firmware Upgrade

Procedure V3.x

1-2

Introduction

ACU Dimensions

7 in H (17.8 cm) x 19 in W (48.3 cm) x 19 in D (48.3 cm)

1.4 Technical Support

The 7200 Antenna Control Unit (ACU) contains context-sensitive, on-line help that
is easily accessible from any menu or submenu in the system by simply pressing
the [HELP] key on the 7200 ACU's front panel. For operational problems, a
troubleshooting guide is provided in Appendix E of this manual.

If any questions or problems arise that are not addressed by the manual or the
online help (provided by pressing the [HELP] key), please contact our technical
support team.

1. Email us at [e-mail].

2. Phone us at [phone].

1.5 Important Safety Information

1.5.1 Explanation of Safety Symbols

Symbol Explanation

Protective Earth/Ground Terminal

Caution, Risk of Electric Shock

Caution, Risk of Danger.
Consult accompanying documents.

1.5.2 Technical & Environmental Specifications

ACU Mass 26 lbs (11.8 kg)

ACU Maxi mum Power 75 VA

ACU Maximum Operating Altitude 10,000 ft (3,048 m)

1.5.3 User Supplied Power Cord Requirements

If the factory supplied power cable for the ACU is not available, a user supplied
power cord may be used provided it meets the following criteria: #18 AWG, 10A.
The Belden 17742C/10 or equivalent power cord for example is recommended.

1-3

Introduction

1.5.4 Note about connecting/disconnect from mains power.

The main power source supplying power to the rack that the 7200 Antenna
Control Unit is installed in should be easily accessible for disconnect should an
equipment fault occur.

1-4

Introduction

THIS PAGE INTENTIONALLY LEFT BLANK

1-5

Overview

2.0 OVERVIEW OF THE 7200 ACS

2.1 General Information About the 7200 ACS

The 7200 ACS is an antenna pointing system, controlled manually or
automatically, that positions the antenna to receive the peak signal from one or
more communications satellites. The 7200 ACS uses microprocessor technology to
provide accurate antenna positioning, high reliability, and maximum system
flexibility. The system has the capabilities for rapid multiple satellite access, highly
sophisticated predictive tracking with inclined orbit satellites, and EIA/TIA-232E,
EIA/TIA-422B, IEEE-488 (Optional) remote control communications, and 10BASE-T
Ethernet.

In two-axis applications, azimuth (AZ) and elevation (EL) controls are used to
position the antenna. The three-axis applications use AZ, EL, and polarization (POL)
controls to position the antenna and feed assembly. The four-axis applications use
AZ, EL, and two polarizations (POL & 4TH AXIS) to control the position of the
antenna and feed assembly. Variable speed inverters provide two-speed operation
for AZ and EL with continuously variable drive rates over a range of approximately
50 to 1. The 7150 Drive Cabinet houses the drive controls and interfacing
equipment to the 7200 ACS. The 7150 Drive Cabinet is normally mounted on the
antenna foundation.

A large 8-inch by 4-inch electro-luminescent display and a sensible, uncluttered
keypad form a user interface which is fully menu-driven and includes context­sensitive help messages. With much detail paid to the man-machine interface, the
7200 ACU provides straightforward access to an extremely versatile ACS.

The 7200 offers a number of operational modes including manual jog control,
several programmed positioning modes, "conventional" steptrack, and the
revolutionary Orbit Prediction Track (OPT) mode. OPT provides tracking
performance approaching that of monopulse control systems by combining efficient
steptrack operation with advanced orbital propagation algorithms to produce a
state-of-the-art, predictive tracking method. With OPT, the 7200 provides highly
accurate tracking with minimal initial data (approximately 1.25 hours for initial
model development).

Two-speed motor control is provided as standard equipment, not through the use
of expensive clutched arrangements or dual-wound drive motors, but with standard
three-phase induction motors, controlled by solid-state variable frequency inverters.
This approach not only provides a reliable and cost-effective means of two-speed
operation (with ratios of up to 50 to 1), but also allows for more precise
positioning than conventional Alternating Current (AC) motor control systems
which simply use contactors to switch motor power on and off. This is a result of
the ability of the inverter to "ramp" the motor speed up or down in a controlled
manner rather than simply removing motor power while at full speed. This can
result in uncontrollable coasting and inevitable "overshoot" of the target.

2-1

Overview

FEATURE

DESCRIPTION

th, RMS, in Steptrack mode.
Nominally 5% of receive 3 dB beamwidth, RMS, with valid model in OPT mode
(independent of orbit inclination).

1) (Standard) Absolute, single-speed, brushless resolvers (size 11) and 16-bit monolithic

speed, brushless resolvers (size 20) and paired LSI

3) (Optional) Absolute optical encoders w/accuracies to ±0.004° over 360° range.

Display Resolution

0.01° Standard – Single speed resolvers
Repeatability

(two factory configurations available):

Antenna Control Unit (Rack Mount): 100-240 VAC, 50-60 Hz; 75 VA (Nominal)

Horsepower Range

1/2 to 20 HP; Others available per special order

GDST Model DTR - Serial Port (Standard) EIA/TIA-232E or EIA/TIA-422B.

Contact closure outputs available for selection of up to four beacon signals for legacy
fixed frequency receivers.

Interface

(Optional) IEEE-488 GPIB (General Purpose Interface Bus).

Normally closed dry contacts, ratings:

Maximum Switched Power 62.5 VA

*ACU/drive cabinet interface (1) 25/C, #22 AWG

requirement

An optional cable allows the user to remotely control the antenna axes, using the
Portable Maintenance Control Unit (PMCU) located in the 7150 drive cabinet.

2.2 System Specifications

As shown in Table 2-1, the 7200 ACS has specifications that reflect performance
sufficient for virtually any communications system antenna, as well as Tracking,
Telemetry, and Control (TT&C) applications. Tracking accuracy within 5 percent of
the receive antenna beamwidth are achievable due to the advantages provided in
the sophisticated OPT modeling. The overall tracking accuracy is related to the
resolution of the angular position display system, which is configured according to
individual system requirements.

TABLE 2-1 7200 ACS SPECIFICATIONS

Nominally more than 10% of receive 3 dB beamwid

Tracking Accuracy

Position Encoding

Front Panel Position

Position Encoding

Input Power
Requirements

ACU Tracking
Receiver Interface

Remote
Communications

Summary Alarm
Output

LSI tracking resolver-to-digital conversion IC's with 0.02° RMS accuracy.

2) (Optional) Absolute, electrical two­tracking resolver-to-digital conversion IC's with 0.01° peak accuracy.

0.001° (Optional - Available only with two-speed resolvers or optical encoders.)

Typically 1 LSB of resolver-to-digital conversion resolution

Drive cabinet

1) 208-240 VAC, three-phase, 50-60 Hz, 5-wire WYE.

2) 380-415 VAC, three-phase, 50-60 Hz, 5-wire WYE.

Drive Cabinet current requirements are determined by the motor horsepower.

GDST Model 253 - Analog: Single 0 to 10 VDC analog input;

10BASE-T Ethernet Port (IEEE 802.3) for remote monitor and control.
Or EIA/TIA-232E 115.2 kbps max. or EIA/TIA-422B (115.2 kbps max.)

Maximum Voltage 220 VDC or 125 VAC.
Maximum Switched Current 1 Amp

*Resolver/ACU (2) three-shielded pair, #22 AWG (two-axis systems)
System
Interconnect
Cabling

2-2

*(3) three-shielded pair, #22 AWG (three-axis systems)

*100 feet of interconnect cabling

*Additional cabling is available up to a maximum length of 1500 feet

*Two-speed and optical encoding systems cabling requirements specified for each

Overview

FEATURE

DESCRIPTION

Humidity - 100% condensing.

TABLE 2-1 7200 ACS SPECIFICATIONS

Antenna Control Rack-mounted Unit:

Temperature - 0°C to + 50°C; Humidity - 90% non-condensing

Environmental

Specifications subject to change without notice.

Drive Cabinet:

Temperature (Standard) -10°C to +50°C
Temperature (Optional) -40°C to +50°C (Low temperature package)

2.3 System Configuration

Refer to Figure 2-1 for a typical overall block diagram of the integrated control
system. Items shown with solid interconnection lines represent fundamental
system components that provide automatic positioning for a two-axis system.
Items connected with a dashed line represent typical system options such as a
tracking receiver, POL motorization components, Customer-Furnished Equipment
(CFE), and remote Monitor and Control (M&C) equipment.

Figure 2-1 Typical 7200 ACS Block Diagram

2-3

Overview

The standard main input voltage for the drive cabinet is either 208 VAC three­phase WYE, or 380 - 415 VAC three-phase WYE requiring a four-wire circuit plus a
ground conductor. The actual current/power requirements for a given system are
essentially established by the drive motor characteristics with only a small portion
being used for control logic power. Other input voltages and frequencies are
available as options, as is single-phase input power (the drive motors remain three­phase in this case as the inverter modules perform the required conversion). The
input power wiring connects to pressure-type lug terminals on the main circuit
breaker housing inside the drive cabinet.

NOTE: In all cases, power wiring to the drive cabinet

must be sized for the rated currents and voltage drop and installed
by qualified personnel in accordance with local codes.

Power for each of the drive motors is supplied from the drive cabinet through
double insulated cables which are run through conduit and other enclosures serving
as cable plenums and pull boxes. The motor power conductors connect to
pressure-type lugs on terminals in the drive cabinet and in the motor junction
boxes. Motor power wiring is sized for rated currents and voltage drops and is
protected by overcurrent devices as defined by the regulations of the National
Electrical Code (NEC), International Electrotechnical Commission (IEC), and
Institute of Electrical and Electronic Engineers (IEEE).

Overtravel limit switches for each axis are interfaced with the drive cabinet via
double insulated control cabling. In the drive cabinet, drive interlock logic is
provided for each direction of travel and a summary limit alarm is developed and
provided to the ACU for display. The limit switch cables connect to pressure-type
terminals at each limit switch and in the drive cabinet.

Axis drive commands and drive cabinet status signals are passed between the ACU
and drive cabinet through a 25 conductor, #22 AWG cable with a maximum length
of 1500 feet. The cable connects to a pressure-type terminal strip in the drive
cabinet and terminates into a 25-pin female D-connector at the rear of the ACU.

The AZ, EL, and POL (three-axis systems) and AZ, EL, POL and 4TH AXIS (four­axis systems) transducers interface directly with the ACU via a shielded
multiconductor cable for each device. The standard configuration includes single­speed, brushless resolvers that require three twisted pair cables. The cables
terminate to flying leads at the resolver via solder or positive crimp connections
and terminate into male D-connectors at the ACU end (25-pin for AZ and EL; 9-pin
for POL). Other types of position transducers, including high accuracy two-speed
resolvers and absolute optical encoders, are available as options to accommodate
critical antenna pointing accuracy requirements or to provide additional resolution
for narrow beamwidths.

2-4

Overview

In applications requiring closed-signal-loop tracking (Steptrack and OPT), a serial
connection between the General Dynamics DTR tracking receiver and the 7200
ACU provides the ACU with the beacon signal level. Alternatively, an analog
tracking signal is accepted through the ACU rear panel via J21 (a 9-pin D­connector). The nominal tracking voltage input is in the range of 0 to 10 VDC,
with a slope of 0.2 V/decibels (dB) to 1.0 V/dB. Beacon select outputs are
provided on a 7200 ACU rear panel terminal strip (TB1), allowing remote manual or
automatic beacon selection with General Dynamics tracking receivers.

Full function remote control of the tracking system is facilitated through the
10BASE-T Ethernet port or one of the serial ports (both EIA/TIA-232E and EIA/TIA­422B are provided). An IEEE-488 (also known as GPIB), interface is also available
as a factory option.

A summary alarm contact is provided on the ACU rear panel user interface terminal
strip TB1. The contact can be wired to a warning light, buzzer or M&C interface to
alert the station operators that the 7200 ACU has a summary fault condition.

2.4 System Hardware

The 7200 ACS consists of the following subsystems:

• Model 7200 ACU

• 7150 Drive cabinet

• Position Feedback Devices

The system interfaces with three-phase induction motors for AZ and EL positioning
and a single-phase AC synchronous stepping motors for POL rotation. Limit
interfaces are for normally closed switches that open upon engagement.

2-5

Overview

Front Panel Display Assembly

Rear Panel PCB

Keyboard Controller PCB

One Power Supply

Digital I/O Daughter PCB

VCPU PCB

Optical Encoder PCB (Optional)

Single/Dual-Speed RDC PCB (Optional)

Optical Encoder I/O PCB (Optional)

2.4.1 7200 ACU Hardware

The Model 7200 ACU is a technically advanced, specially designed, multitasking
embedded control computer that includes input and output circuitry sufficient for
interfacing with all other related tracking system components. The ACU hardware
is based upon the industrial Versa Module Europe (VME64 (VITA 1-1994)) bus
architecture, providing extreme versatility and reliability far above many other
hardware platforms. Several printed circuit cards and peripheral subassemblies,
described in subsequent sections, are integrated in a custom chassis to comprise
the ACU. The primary components of the 7200 ACU are:

•

•

•

•

•

•

•

The 7200 ACU front panel is shown in Figure 2-2. The 7200 ACU functional block
diagram is shown in Figure 2-3. Figures 2-4 and 2-5 show the top and side view
of the ACU respectively. (Refer to the engineering drawings in Section 7.0)

•

•

Figure 2-2 7200 Antenna Control Unit Front Panel

2-6

Overview

Figure 2-3 7200 ACU Functional Block Diagram

2-7

Overview

Figure 2-4 7200 Antenna Control Unit Top View

Figure 2-5 7200 Antenna Control Unit Side View

2-8

Overview

2.4.1.1 VertexRSI Central Processing Unit (VCPU) PCB Assembly

The 7200 ACU uses the Motorola 68030 32-bit microprocessor as the Central
Processing Unit (CPU), providing sufficient computing power for the sophisticated
control and tracking algorithms used by the ACU. A dedicated VME CPU circuit
card is provided, which includes the CPU, Read-Only Memory (ROM), Random
Access Memory (RAM), bus control circuitry, and nonvolatile memory control
circuitry, providing efficient and reliable system operation.

The VCPU card has several indicators and switches mounted on the VME front
panel to provide the user with basic diagnostic information.

Figure 2-6 VCPU Card

D1 Halt LED – This bi-color green/red LED indicates the operational status of the

68030 CPU. If this LED is red the processor is halted and the system will not
operate, consult the factory for assistance. This LED will always be illuminated
green even when the board is held in reset.

D4 Reset LED – This bi-color green/red LED indicates the reset status of the board.
If this LED is red it means the board is in reset. The following events can cause a
reset condition to occur:

1) 2.5 VDC undervoltage fault – If this is the cause then LED D2 (SMT LED

located between the battery and the left hand side of the board) will be
extinguished indicating that the 2.5V power supply source has fallen below

2.38VDC. Check the voltage to ensure it is above 2.38VDC. Potentiometer PT1
sets the threshold for this fault (Re-adjust per General Dynamics document CG-

0283).

2) 3.3 VDC undervoltage fault – If this is the cause the battery monitor IC (U1)

has detected a voltage lower than 2.9 VDC. Check the 3.3V regulator output
(VR1) to see if 3.3V is the output voltage.

3) 5.0 VDC undervoltage fault – If this is the cause then LED D3 (SMT LED

located between the battery and the left hand side of the board) will be
extinguished indicating that the 5.0V power supply source has fallen below

4.75VDC. Check the voltage to ensure it is above 4.75VDC. Potentiometer
PT2 sets the threshold for this fault (Re-adjust per General Dynamics document
CG-0283).

4) Dip Switch S6 pos 6 in the ON position – Leaving this dip switch in the ON

position holds the board in reset; change the position of the switch to the OFF
position to allow the board to operate normally.

2-9

Overview

S2 SWITCH POSITION

DESCRIPTION

up, run the MONDO Monitor program. MONDO is a low level monitor

up, test and program a new 7200

5) Momentary Pushbutton switch S1 is pressed – This switch is spring loaded so

it should not be able to remain pressed in (which will hold the board in reset);
however, if it were to be held in place by something mechanically binding it,
then the board would remain in reset; press the reset push button switch S1
several times to ensuring that it is springing back out with each release.

Reset Switch S1 - The momentary reset switch allows the user to reset the system
CPU. Resetting the board is similar to cycling the power on the unit except the
main RAM bank of memory on the board is not erased (as it is when the power is
cycled). This reset switch is mainly used by General Dynamics software
development personnel but can also be used by site operators when
troubleshooting.

Hex Rotary Switch S2 – This rotary switch is used to determine which firmware to
run when the system is powered on. The VCPU contains enough flash memory to
hold four unique versions of application code (each of these four allocations in
memory is referred to as a boot bank). This is useful when upgrading the 7200
ACU firmware because the new image can be uploaded to another boot bank, the
rotary switch can be changed, and the ACU can be booted up with the new
application firmware without erasing the original factory supplied application code.
The rotary switch positions and their respective functions are defined in the table
below:

TABLE 2-2 VCPU S2 HEX ROTARY SWITCH POSITIONS DEFINITION

0 (Factory Setting) On power-up, run the application firmware contained in boot bank 0.

1 On power-up, run the application firmware contained in boot bank 1.

2

3

4 - D Unused (currently these positions are treated like position E).

E

F

On power-up, run the application firmware contained in boot bank 2.

On power-up, run the application firmware contained in boot bank 3.

On power­program used by General Dynamics to power­ACU. MONDO uses an ASCII based protocol to interface with a PC via a terminal
program via serial port 0 (front panel display or serial port 1 – J14 on the rear of the

7200).

On power-up, run the Swift X talker (Used by General Dynamics software developers
only)

Hex Rotary Switch S3 – This rotary switch is used to determine which self-test the
VCPU will run when powered up. The VCPU contains self test code which are
divided into three categories:

1) Destructive Tests – These tests erase memory, which would cause the user to

have to reload the parameters and application code.

2) Independent Tests – These tests can be run without the need for external test

cables and other test hardware. The following circuits are functionally tested:
floating point coprocessor, real time clock, serial ports (loopback internal to the

2-10

Overview

S3 SWITCH POSITION

DESCRIPTION

S6 SWITCH POSITION

OFF POSITION (SWITCH OPEN)

ON POSITION (SWITCH CLOSED)

S4 SWITCH POSITION

OFF POSITION (SWITCH OPEN)

ON POSITION (SWITCH CLOSED)

UART), CPU interface to the Ethernet controller microcontroller, the rotary
switches S2, S3 and the dip switch S4.

3) Dependent Tests – These tests require special test jigs and are run by factory

personnel to verify operation of the system.

This self-test code is only run if DIP switch S4 pos 8 is in the ON position. To
prevent against “accidentally” running these tests, the tests are also interlocked
with the Keyboard controller card. If the keyboard controller card is detected, the
tests will be aborted. The serial port between the keyboard controller card and the
display controller card should be unplugged to allow the tests to proceed.

TABLE 2-3 VCPU S3 HEX ROTARY SWITCH POSITIONS DEFINITION

0 (Factory Setting) On power-up, no self-test code is run.

1 On power-up, the destructive suite of tests is run.

2

3

4 - E Unused.

F On power-up, run all tests sequentially.

On power-up, the independent suite of tests is run.

On power-up, the dependant suite of tests is run.

DIP Switch S6 – This DIP switch directly controls various hardware related board
functions as defined in the following table:

TABLE 2-4 VCPU S6 DIP SWITCH POSITIONS DEFINITION

1 - 4

5

6

7

Flash Write Disabled ♦♥
EEPROM Write Disabled♦
Normal Operation♦
CPU Watchdog Disable♦

8 Board Reset Disabled

♦ Denotes the normal operating position of the switch (factory setting).
♥To program the flash boot banks with new application code, S6 pos 1-4 must be in the ON position; after programming is
complete, return these four switches to the OFF position.

Flash Write Enabled

Hold the VCPU board in Reset

CPU Watchdog Enable
Board Reset Enabled♦

DIP Switch S4 – This DIP switch controls various software functions as defined in
the following table.

TABLE 2-5 VCPU S4 DIP SWITCH POSITIONS DEFINITION

1 Password Protection Enabled♦ Password Protection Disabled

2-6 Unused♦

7 Standard Boot Up ♦

8 Self Test Mode Disabled♦ Self Test Mode Enabled♠

♦ Denotes the normal operating position of the switch (factory setting).
♠ Enabling self-test mode should ONLY be performed when directed to do so by General Dynamics technical support. Some
of the self-tests erase NVRAM (parameter storage space) and some erase all the flash banks (application firmware).

Resets all params to factory defaults on Boot

2-11

Overview

Potentiometer PT3 – The analog input circuit contains an AGC gain amplifier. The
gain of this amplifier is adjusted by PT3. To use the AGC gain amplifier, the shunt
plug on 201358-01 site J4 must be moved from the “Bypass” position (factory
setting) to the “Gain” position. Refer to the A/D Calibration section of General
Dynamics Document #CG-0283.

2-12

Overview

Description

Typical

Calculated Worst Case

Potentiometer PT4 – The analog input circuit contains a zero offset calibration

potentiometer PT4. Refer to the A/D Calibration section of General Dynamics
Document #CG-0283.

Potentiometer PT5 – The analog input circuit contains a gain calibration
potentiometer PT5. Refer to the A/D Calibration section of General Dynamics
Document #CG-0283.

Table 2-6 provides miscellaneous performance specifications that are inherent to
the VCPU board.

TABLE 2-6 VCPU PERFORMANCE SPECIFICATIONS

Real Time Clock Accuracy

(A TCXO drives this clock)

NVRAM Battery Backup Shelf Life
(external power source off)

NVRAM Battery Backup

Normal Operation (external power
source operational)

Battery Change Period (without
NVRAM corruption) *

* A capacitor keeps the NVRAM powered while the battery is being replaced. This row in the table defines the minimum

amount of time that the discharging capacitor will keep the NVRAM powered without the battery present.

+/- 0.16 Seconds/Day

24 Months

-

>45 Seconds >21 Seconds

+0.26 to –0.42 Seconds/Day

(@ 0-50 Degrees C)

15 Months

(@ 0 Degrees C)

90% capacity after 10 years due to
self discharge

(@ 25 Degrees C)

2.4.1.2 User Interface

One of the most striking and advanced features of the 7200 ACU is the user
interface, which combines an 8-inch by 4-inch electroluminescent display with a
custom 24-station keypad to provide the most straightforward, powerful, and user­friendly operating platform in the industry. As shown in Figure 2-2, the 7200 ACU
front panel layout is uncluttered and offers a logical format for the display of
information. For more information on the user interface refer to Section 2.5.1.

2.4.1.3 Digital Input/Output Printed-Circuit Board Assembly

The I/O PCB provides the electrical interface between the ACU and the drive
cabinet. In addition, the I/O card serves as the interface between the CPU and the
ACU rear panel status inputs and control outputs. There are a total of 24 digital
inputs (some inputs are used internally so all 24 are not available through the rear
panel connectors). See table 2-7 for the digital inputs specifications.

2-13

Overview

CONNECTOR TB1 ONLY

CONNECTORS J10 & J11

TABLE 2-7 7200 DIGITAL I/O SPECIFICATIONS

DIGITAL INPUTS DESCRIPTION

Voltage Levels

Input Impedance 10 K Ohms (Nominal)

Transient Voltage Suppression

DIGITAL OUTPUTS

Output Type Relay Contact Closure

Maximum Input Voltage 220 VDC or 125 VAC RMS

Maximum Load Current 1 Amp

Maximum Switched Power 62.5 VA

DIGITAL I/O

Output Type Open Collector Transistor

Maximum Input Voltage 26.7 VDC

Maximum Load Current 500 mA

Transient Voltage Suppression

Specifications subject to change without notice.

Logic Level High Voltage Range: (+4.5 to +26.7 VDC)

Logic Level Low Voltage Range: (0 to +1 VDC)

Electrostatic discharge (ESD) as defined in IEC 1000-4-2,

Electrical fast transients (EFT) per IEC 1000-4-4

Electrostatic discharge (ESD) as defined in IEC 1000-4-2,

Electrical fast transients (EFT) per IEC 1000-4-4

DESCRIPTION

DESCRIPTION

2.4.1.4 Resolver-to-Digital Converter Printed-Circuit Board Assembly

The Resolver-to-Digital Converter (RDC) PCB accepts analog inputs from the
antenna-mounted AZ, EL, and/or POL resolvers (via the rear panel termination
circuit card) and provides a binary digital encoded representation of the pointing
angles for each axis to the CPU. VME bus interface circuitry is included, based
upon CPU and RDC timing requirements. The standard configuration is for single­speed resolvers and 16-bit encoding; however, the RDC PCB can be configured to
accept dual-speed resolver inputs and provide higher resolution as required.
Alternate means of position encoding are available, including high accuracy
absolute optical encoders, in which case an alternate position interface circuit card
is provided.

2.4.1.5 Optical Encoder Daughter Board (Optional - AZ and EL)

The OE daughter card is mounted on its own VME card. This card takes the EIA­422A serial encoder data and converts it to 24 bits for use by the CPU. Two
Complex Programmable Logic Devices (CPLDs) are employed to convert the buffered
serial data to parallel data for use by the CPU. The card reads each encoder about
4000 times per second. The bits of position resolution are dependant on the actual
optical encoder used, however, most optical encoder systems have 18 bits of
resolution.

2-14

Overview

2.4.1.6 Dual Channel Resolver-to-Digital Converter PCB Assembly

(Optional POL and 4TH AXIS)

The Resolver-to-Digital Converter (RDC) PCB accepts analog inputs from the
antenna-mounted resolvers (via the rear panel termination circuit card) and provides
a binary digital encoded representation of the pointing angles for the POL and 4TH
AXIS to the CPU. VME bus interface circuitry is included, based upon CPU and
RDC timing requirements. The standard configuration is for single-speed resolvers
and 16-bit encoding.

2.4.1.7 IEEE-488 Interface (Optional)

The IEEE-488 bus has been optionally incorporated into the 7200 ACU to
accommodate users wishing to utilize this type of interface. The IEEE-488 bus
allows connectivity between different programmable devices with a standard
interface for communications between each instrument. The IEEE-488 interface is
also known as GPIB (General Purpose Interface Bus) or HPIB (Hewlett Packard
Interface Bus), and is electrically similar to IEC-625. Please refer to document CG­6041 for M&C protocol for this interface.

2.4.1.8 Time and Frequency Processor Board (Optional)

The 7200 ACU clock accuracy can be precisely maintained by utilizing the optional
Time and Frequency Processor Board. This VME board is used in conjunction with
an external (CFE) time source to synchronize the 7200 ACU clock to the accurate
time source. The external time source sends an IRIG-B compliant signal to the J3
BNC connector on the rear of the 7200 ACU. This signal is routed to the Time and
Frequency Processor Board (TFP). The VCPU board acquires only the year from
the on-board real-time clock while the rest of the time/date information is taken
directly from the TFP board. If the TFP board becomes disconnected from its
source, a message will be displayed on the ACU “External Timing Source Lost”.

2.4.1.9 ACU Chassis Assembly

The ACU is housed in a custom chassis assembly which mounts in a standard 19­inch Electronics Industry Association (EIA) rack, requiring 7-inches of vertical rack
space (4 Rack Units per EIA 310). The nominal overall dimensions of the ACU
chassis are: 7-inches tall by 19-inches wide by 20-inches deep. The 7200 ACU’s
weight is approximately 27 lbs. A four-slot VME card cage, which houses the
VCPU, I/O, and RDC PCB’s, is mounted to the inside of the chassis top plate. The
top plate is hinged at the rear of the chassis and includes a locking support arm to
facilitate convenient front-side access to the card cage. Studs connected to the
front panel support the front panel display and keypad and their respective control
circuit cards.

2-15

Overview

AC POWER INPUT

DESCRIPTION

A VME backpanel PCB serves as the bus interface and DC power supply
distribution system for the CPU and RDC PCB’s. Two of the four slots are available
for future expansion and/or customized features and factory options.

A PCB mounted to the ACU rear panel accepts all external wiring and connectors
(with the exception of the line cord) and serves as a “break-out” device with
connections to each of the circuit boards in the card cage.

Two cooling fans are provided to ensure operation of the ACU internal components
remain well within device ratings. The fans are powered from the +24 V output of
the power supply.

2.4.1.10 Power Supply, EMI Filter and Fuse

Power for all ACU components is provided by one power supply assembly, which
is mounted to the bottom plate of the chassis. This power supply is a quad
output, switched mode type, providing output voltages of +5, ±12 and +24 VDC
for all logic and control circuits. Nominal power requirements for the ACU are 75
VA at 100 to 240 VAC, 50 or 60 Hertz (Hz).

The power supply used in the 7200 ACU has an automatic shutdown feature in
case over-current conditions occur. The system also has a line fuse on the rear
power entry module in case of a ground fault. An input line-conditioning filter
provides Electromagnetic Interference (EMI) suppression.

TABLE 2-8 7200 POWER INPUT SPECIFICATIONS

Input Voltage Range 100 to 240 VAC Nominal

Input Power Requirements 75 VA Typical

Input Surge Current 25 Amps Max. @ 25 degrees C

Input Power Factor 0.98 Typical (Active Power Factor Corrected Supply)

Input Frequency Range 50 to 60 Hz Nominal (47-63 Hz Max.)

Fuse Current Rating 2 Amps

Fuse Type 5 x 20 mm Time Lag Fuse (Slo-Blo Type Fuse) per IEC 60127-2 Sheet 3

Specifications subject to change without notice.

2.4.2 Antenna Drive Cabinet Hardware

The standard motor drive cabinet is a freestanding, foot-mounted aluminum NEMA­4X enclosure with overall dimensions of approximately 36-inches tall by 30-inches
wide by 10-inches deep (91.4 cm tall by 76.2 cm wide by 25.4 cm deep). The
aluminum cabinet provides outstanding corrosion protection even in the harshest of
environments. The cabinet weighs approximately 150 lbs. (68 kg) and is
operational in altitudes of up to 10,000 ft. (3,048 m). The input power to the
cabinet can vary according to the particular drive cabinet that was ordered with
your system; please see the specific system documentation for more information.

2-16