HP RC3000 User Manual
RC3000 MOBILE ANTENNA CONTROLLER
USER’S MANUAL
Contents subject to change
1 December 2005
RESEARCH CONCEPTS INC.
5420 Martindale Road
Shawnee, Kansas 66218-9680 USA
VOICE: (913) 422-0210
FAX: (913) 422-0211
www.researchconcepts.com
support@researchconcepts.com
Serial No________
REVISION HISTORY
DATE MODIFICATION SOFTWARE VERSION
8 March 1999 Preliminary document 1.00
13 April 1999 Initial Release 1.04
1 June 1999 Update 1.07
13 March 2000 Software Update 1.16
15 November 2002 Chapter 2 Update 1.37
10 January 2003 Appendix E Update 1.38
3 January 2005 Manual Format Update 1.46
1 December 2005 Software Update 1.55
WARRANTY INFORMATION
Research Concepts, Inc.(RCI) warrants to the original purchaser, this product shall be free from defects
in material and workmanship for one year, unless expressed otherwise, from the date of the original
purchase.
During the warranty period, RCI will provide, free of charge, both parts and labor necessary to correct
such defects.
To obtain such a warranty service, the original purchaser must:
(1) Notify RCI as soon as possible after discovery of a possible defect, of:
(a) the model and serial number
(b) identify of the seller and date of purchase
(c) detailed description of the problem, including details on the electrical connection to associated
equipment and list of such equipment, and circumstances when problem arose.
(2) Deliver the product to RCI, or ship the same in its original container or equivalent, fully insured
and shipping charges prepaid.
Correct maintenance, repair, and use are important to obtain proper performance from this product.
Therefore, read the instruction manual carefully and completely. This warranty does not apply to any
defect that RCI determines is due to:
- Improper maintenance or repair, including the installation of parts or accessories that do not
conform to the quality and specifications of the original parts.
- Misuse, abuse, neglect, or improper installation including disregard for installation of backup or
safety override equipment.
- Accidental or intentional damage.
- Lightning or acts of God.
There are no implied warranties.
The foregoing constitutes RCI's entire obligation with respect to this product, and the original purchaser
and any user or owner shall have no other remedy and no claim for incidental or consequential damages.
Some states do not allow limitations or exclusions of incidental or consequential damages, so the above
limitation and exclusion may not apply to you. This warranty gives you specific legal rights and you may
also have other rights which may vary from state to state.
RCI retains the right to make changes to these specifications any time, without notice.
Copyright – Research Concepts Inc., 2005
REPAIR RETURN INFORMATION
To help guarantee a fast and efficient repair, the user should request and receive a Return Merchandise
Authorization number (RMA#) from Research Concepts Inc. prior to shipping the unit.
In addition, international returns are required to complete the correct documents necessary for achieving
U.S. Customs clearance. In order to avoid duties and taxes, export documents must be accurately
completed to meet Export Administration Regulations. Contact RCI for guidance with respect to the
correct completion of shipping documents.
TABLE OF CONTENTS
1.0 INTRODUCTION.................................................................................................................................................1
1.1 MANUAL ORGANIZATION.....................................................................................................................................1
1.2 RC3000 FEATURES ..............................................................................................................................................3
1.3 THEORY OF OPERATION .......................................................................................................................................5
1.3.1 Controller Description.................................................................................................................................5
1.3.2 System Interface Requirements ....................................................................................................................6
1.3.3 Operational Overview..................................................................................................................................7
1.3.4 Antenna Pointing Solution ...........................................................................................................................9
1.3.5 Timekeeping ...............................................................................................................................................11
1.3.6 Drive System...............................................................................................................................................11
1.3.7 Polarization Control ..................................................................................................................................13
1.3.8 Magnetic Variation ....................................................................................................................................14
1.3.9 System Performance...................................................................................................................................15
1.4 SPECIFICATIONS .................................................................................................................................................16
2.0 INSTALLATION................................................................................................................................................17
2.1 EQUIPMENT MOUNTING .....................................................................................................................................18
2.1.1 RC3000 Antenna Controller.......................................................................................................................18
2.1.2 GPS Receiver..............................................................................................................................................19
2.1.3 Fluxgate Compass......................................................................................................................................20
2.1.4 Electronic Clinometer ................................................................................................................................22
2.2 ELECTRICAL CONNECTIONS ...............................................................................................................................24
2.2.1 Power Entry................................................................................................................................................25
2.2.2 Motor Drive................................................................................................................................................26
2.2.3 Drive Sense.................................................................................................................................................27
2.2.4 Limit Switches ............................................................................................................................................28
2.2.5 Signal Strength...........................................................................................................................................29
2.2.6 Navigation Sensors.....................................................................................................................................30
2.2.7 Accessories.................................................................................................................................................31
2.2.8 RF Autopeak...............................................................................................................................................32
2.2.9 Hand Held Remote.....................................................................................................................................33
2.2.10 Pulse Sensors ...........................................................................................................................................35
2.2.11 Remote Control ........................................................................................................................................38
2.2.12 Waveguide Switch ....................................................................................................................................39
2.2.13 Resolver Inputs.........................................................................................................................................40
2.3 INITIAL CONFIGURATION....................................................................................................................................41
2.3.1 Software Initialization................................................................................................................................41
2.3.2 Elevation Calibration.................................................................................................................................43
2.3.3 Azimuth Calibration...................................................................................................................................47
2.3.4 Polarization Calibration ............................................................................................................................50
2.3.5 Fast/Slow Motor Speed ..............................................................................................................................53
2.3.6 Pulse Sensor Checkout...............................................................................................................................53
2.3.7 Drive System Checkout...............................................................................................................................53
2.3.8 Navigation Sensor Communication............................................................................................................53
2.4 FINAL CALIBRATION ..........................................................................................................................................54
2.4.1 Compass Calibration..................................................................................................................................54
2.4.2 Azimuth and Elevation Alignment..............................................................................................................55
2.4.3 Signal Strength Adjustment........................................................................................................................57
2.4.3.1 L-Band Power Detector .........................................................................................................................................57
2.4.3.2 Signal Strength Channel ........................................................................................................................................57
2.4.3.3 Signal Strength Channel Calibration......................................................................................................................58
2.4.3.4 Amplifier Gain vs. Frequency Characterization ....................................................................................................59
2.4.4 Pulse Scale Factors....................................................................................................................................60
2.4.5 Operational Presets....................................................................................................................................62
2.4.6 Miscellaneous Adjustments ........................................................................................................................62
2.4.7 Mechanizing Automatic Locates ................................................................................................................62
3.0 DETAILED OPERATION ................................................................................................................................ 63
3.1 OPERATION OVERVIEW...................................................................................................................................... 63
3.1.1 Modes......................................................................................................................................................... 63
3.1.2 Keypad Usage............................................................................................................................................ 64
3.1.3 Data Entry ................................................................................................................................................. 66
3.1.4 Display Layout........................................................................................................................................... 67
3.2 OPERATING GROUP............................................................................................................................................ 68
3.2.1 Manual Mode............................................................................................................................................. 69
3.2.1.1 Heading Fix........................................................................................................................................................... 71
3.2.1.2 Waveguide Switch................................................................................................................................................. 72
3.2.2 Menu Mode................................................................................................................................................73
3.2.2.1 Deploy................................................................................................................................................................... 74
3.2.2.2 Stow....................................................................................................................................................................... 75
3.2.2.3 Locate.................................................................................................................................................................... 76
3.2.2.3.1 Satellite Selection........................................................................................................................................... 77
3.2.2.3.2 LOCATE Automatic Movement............................................................................................ ........................ 79
3.2.2.3.3 Azimuth Scanning Autopeak ......................................................................................................................... 80
3.2.2.3.4 Spiral Search Autopeak.................................................................................................................................. 82
3.2.2.3.5 Terminal Peak Up.......................................................................................................................................... 83
3.2.2.3.6 Polarization Tilt Compensation...................................................................................................................... 83
3.2.2.4 Store ...................................................................................................................................................................... 84
3.2.2.5 Recall..................................................................................................................................................................... 85
3.2.2.6 Delete .................................................................................................................................................................... 85
3.2.2.7 Position.................................................................................................................................................................. 86
3.2.2.7.1 LAT/LON ...................................................................................................................................................... 86
3.2.2.7.2 HEADING ..................................................................................................................................................... 87
3.2.2.7.3 INIT ............................................................................................................................................................... 87
3.2.2.8 Settings.................................................................................................................................................................. 89
3.2.2.9 Track ..................................................................................................................................................................... 90
3.2.2.10 Remote ................................................................................................................................................................ 90
3.2.2.11 VSAT Mode........................................................................................................................................................91
3.3 PROGRAMMING GROUP...................................................................................................................................... 94
3.3.1 Configuration Mode................................................................................................................................... 94
3.3.1.1 NORMAL ACCESS ITEMS................................................................................................................................. 96
3.3.1.1.1 Expert Access Permission.............................................................................................................................. 96
3.3.1.1.2 Preset Locations............................................................................................................................................. 97
3.3.1.1.3 Preset Satellites.............................................................................................................................................. 98
3.3.1.2 INSTALLATION ACCESS ITEMS..................................................................................................................... 99
3.3.1.2.1 System Definition .......................................................................................................................................... 99
3.3.1.2.2 Elevation Calibration ................................................................................................................................... 100
3.3.1.2.3 Azimuth Calibration..................................................................................................................................... 102
3.3.1.2.4 Polarization Calibration ............................................................................................................................... 104
3.3.1.2.5 Signal Strength Factors................................................................................................................................ 105
3.3.1.2.6 Autopeak...................................................................................................................................................... 106
3.3.1.3 Super-User Access Items..................................................................................................................................... 108
3.3.1.3.1 Reset Defaults.............................................................................................................................................. 108
3.3.1.3.2 Azimuth Pot Drive.......................................................................................................................................109
3.3.1.3.3 Azimuth Pulse Drive ................................................................................................................................... 110
3.3.1.3.4 Azimuth Drive Monitoring .......................................................................................................................... 111
3.3.1.3.5 Elevation Pot Drive...................................................................................................................................... 113
3.3.1.3.6 Elevation Pulse Drive.................................................................................................................................. 114
3.3.1.3.7 Elevation Drive Monitoring........................................................................................................................ 114
3.3.1.3.8 Polarization Drive........................................................................................................................................115
3.3.1.3.9 Pol Drive Monitoring................................................................................................................................... 115
3.3.1.3.10 Stow & Deploy Positions........................................................................................................................... 116
3.3.1.3.11 SHAKE...................................................................................................................................................... 117
3.3.2 Maintenance Items................................................................................................................................... 118
3.3.2.1 Analog to Digital Voltage ................................................................................................................................... 119
3.3.2.2 Drive Error Resets............................................................................................................................................... 120
3.3.2.3 Time Maintenance............................................................................................................................................... 120
3.3.2.4 Signal Strength Offset Calculator........................................................................................................................ 122
3.3.2.5 Limits Maintenance .............................................................................................................................................123
3.3.2.6 GPS Serial Port Diagnostics ................................................................................................................................124
3.3.2.7 Fluxgate Serial Port Diagnostics.......................................................................................................................... 124
3.3.2.8 MOVETO............................................................................................................................................................125
3.3.2.9 Fluxgate Calibration Procedure ...........................................................................................................................126
3.3.2.10 Shake .................................................................................................................................................................127
3.3.2.11 Configuration Item Record ................................................................................................................................128
3.4 ALARM DISPLAYS ............................................................................................................................................129
4.0 TROUBLESHOOTING....................................................................................................................................131
4.1 LIMIT SWITCHES...............................................................................................................................................131
4.2 MOTOR DRIVE..................................................................................................................................................132
4.3 AUTOMATIC MOVEMENTS................................................................................................................................133
4.4 GPS..................................................................................................................................................................133
4.5 FLUXGATE COMPASS........................................................................................................................................134
5.0 DRAWINGS & SCHEMATICS......................................................................................................................135
APPENDIX A - EXPERT ACCESS / RESET DEFAULTS CODE
APPENDIX B - MOUNT SPECIFIC DATA
APPENDIX C - DC MOTOR CONTROLLER
The following appendices describe optional features of the RC3000. These appendices will be
included in the manual if the option is present.
APPENDIX REM - REMOTE CONTROL
APPENDIX TRK - INCLINED ORBIT TRACKING
APPENDIX DVB - INTEGRATED DVB RECEIVER
APPENDIX DSI - ANTENNA DEPLOYMENT SAFETY INTERLOCK
APPENDIX TLE - TWO LINE ELEMENT TRACKING
RC3000 Antenna Controller Chapter 1 Introduction
1.0 INTRODUCTION
The RC3000 antenna controller is designed for use with elevation over azimuth antennas on mobile
satellite uplink vehicles. The RC3000 assists both the technically-oriented and the non-technical operator
of a mobile satellite antenna system by automating the process of locating and locking on to a particular
satellite. This process can be time-consuming due to several factors. For each shoot, the antenna may
be located in a different location, with its own local magnetic variation, and oriented in a different
direction. Since the beamwidth of the antenna is extremely narrow, the elevation and azimuth pointing
angles require a significant degree of accuracy to even be in the neighborhood of the satellite.
The design and function of the RC3000 is derived from two other proven antenna controllers from
Research Concepts Inc.: the RC8097 satellite locator and the RC2000C tracking antenna controller.
This pedigree allows the RC3000 to automate all operational steps within one piece of equipment. First,
a microcontroller based calculator function provides an accurate pointing solution through a collection of
sensor data. The RC3000 then uses the data from the sensors to accurately steer the antenna to the
calculated azimuth and elevation angles. The RC3000 also optionally automates the function of tracking
inclined orbit satellites.
PLEASE READ AND UNDERSTAND THE MANUAL. Due to the complexity of the functions performed
by the RC3000, time invested in understanding its installation and operation will be well spent.
1.1 Manual Organization
This manual contains five chapters and multiple appendices. Each chapter is divided into multiple
sections.
This section (1.1) summarizes the contents of the remainder of the manual and the conventions and
notations used throughout the manual. Section 1.2 highlights the functionality and features of the
RC3000. Section 1.3 reviews the theory of the RC3000’s operation and should be understood before
installation and initial use of the RC3000.
Chapter 2 describes the installation and configuration procedures for the RC3000. The rest of the
manual should be reviewed prior to installation in order to provide context for the installation procedures.
Chapter 3 provides detailed instructions on the operation of the RC3000. This chapter will describe the
data presented and user action required for every operational display screen.
Chapter 4 covers RC3000 error conditions and provides help for system troubleshooting.
Chapter 5 provides RC3000 schematics and drawings.
The appendices provide additional support for working with the RC3000:
Appendix A supplies the expert access codes on a single page, which at management’s discretion, may
be removed to eliminate the possibility of inexperienced users inadvertently corrupting configuration data.
Appendix B provides unique information for a specific mount or family of mounts. Please refer to
appendix B now to note what paragraphs in the base manual are different for your mount.
Appendix C provides information on the applicable motor controller for your mount.
A test data sheet is included with the manual that accompanies a new RC3000 controller. The mount
configuration of a particular controller is noted on the test data sheet.
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RC3000 Antenna Controller Chapter 1 Introduction
MANUAL CONVENTIONS
Throughout the manual, representations of screens the user will see will be shown in the boxed format
that follows:
AZIM: 0.0 STOW SS1: 50 MANUAL
ELEV: -67.5 STOW SAT:TELSTAR 402
POL: 0.0 SPD:FAST CST
<0-9>JOG ANTENNA <MODE>MENU 14:25:47
The following table shows typical abbreviations used both on RC3000 screens and in the manual’s text.
ITEM ABREVIATION(S)
Azimuth AZ
AZIM, Azim
Elevation EL
ELEV, Elev
Polarization PL
POL, Pol
Clockwise CW
Counter-Clockwise (Anti-Clockwise) CCW
Down DN
Latitude LAT
Longitude LON
Satellite SAT
Global Positioning System GPS
Liquid Crystal Display LCD
Automatic Gain Control AGC
Satellite longitudes are presented in degree/decimal degree (79.0 W) format since that is the standard
representation of satellite position. Latitude and longitude of the mount are presented in degree/minute
(38°56 N) format.
When referring to a particular RC3000 mode of operation, that mode’s name will be capitalized – ex.
LOCATE.
Throughout the RC3000 manual and software, the latitude, longitude and true heading of the mount are
collectively referred to as the mount’s “position”.
Movements of the mount are represented by graphing the azimuth and elevation axes as shown below.
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RC3000 Antenna Controller Chapter 1 Introduction
1.2 RC3000 Features
The RC3000 antenna controller is designed to automate the operation of mobile (both vehicle mounted
and deployable) mounts. Features provided include:
- Automatic azimuth and elevation pointing solution calculation
- Optional GPS receiver for determination of antenna latitude and longitude
- Optional fluxgate compass for determination of antenna centerline heading
- Optional automatic tracking of inclined orbit satellites
- Automatic polarization control of rotating feeds
- Battery backed-up non-volatile memory for storing satellite locations and configuration data
- Automatic repositioning to stored satellites
- Slim 2U rack mounted unit
- Continuous monitoring of antenna drive status
- Optional RS-422/-232 remote control interface
- Support for C, Ku, Ka, L, X - band satellite operations
- 4 row x 40 column Liquid Crystal Display (LCD) for user interface
- 16 key keypad for data entry
The RC3000 supports mounts from multiple antenna manufacturers and provides optional software
configurations. When the RC3000 is powered on, the following identification screen appears for three
seconds.
RC3000A MOBILE ANTENNA CONTROLLER
(c) RESEARCH CONCEPTS INC. 2004
SHAWNEE, KANSAS (USA) 913-422-0210
SW:RC3K-P1-GTN version 1.44
Hardware Configuration. There are two basic versions of the RC3000 hardware. The “A” version is
configured with circuitry to support mounts with low voltage (12-36 VDC) DC motors. The “B” version
supports higher voltage (40-120 VDC) DC motors. Other hardware configurations provide customized
backpanel configurations, etc. Refer to the appendix B (mount specific data).
In late 2004, internal board configurations changed. These changes did not affect interface definitions or
software functionality. RC3000 units with serial numbers larger than 2000 contain the second generation
boards. Typically, low voltage drive units with second generation board configurations may be referred to
as "A2" units vs."A" which designates units with the original board configuration.
3
RC3000 Antenna Controller Chapter 1 Introduction
Software Configuration. The software configuration (SW:) field is presented in the form RC3K-ab-xyz:
RC3K-(Mount Manufacturer/Model #)-(Nav Sensor Option)(Tracking Option)(Remote Option)
Descriptions of the software configuration designations are provided in the following tables:
Mount Manufacturer/Model #
The software within the RC3000 is customized to account for specifics of individual mounts. A particular
mount is referred to by a two character designation with the first character typically associated with the
mount manufacturer and the second character associated with a specific mount/antenna model from that
manufacturer.
CATEGORY DESIGNATION DESCRIPTION
Mount Manufacturer / Letter / # Example: V1 – Vertex 2.4m. DMK
Model Number S1 – SweDish 1.5m. DA
A3 - AVL 1.2m. USA
N1 - Andrew 4.5m. TriFold
As of December 2005, the RC3000 supported over 80 different mount models.
Navigation Sensor Options
The RC3000 may be provided with multiple navigation sensor options. Navigation sensors allow the
RC3000 to determine the mount's latitude, longitude and heading. If no navigation sensors are present,
estimates of this data may be entered manually.
CATEGORY DESIGNATOR DESCRIPTION
Navigation Sensors N No Navigation Sensors supported
G GPS & Fluxgate compass supported
A GPS, Fluxgate and integrated DVB
F GPS and DVB receiver (no compass)
C GPS Compass
receiver supported
Tracking Options
The RC3000 may provide optional support for tracking inclined orbit satellites.
CATEGORY DESIGNATOR DESCRIPTION
Inclined Orbit N Tracking not supported
Tracking T Step & Memory Track supported
E Step & Memory plus Two Line Element
set tracking supported
Remote Control Options
The RC3000 may provide optional support for controlling the mount from a remote (away from the front
panel) location.
CATEGORY DESIGNATOR DESCRIPTION
Remote Control N No Remote Control Supported
R Remote Monitor & Control Supported
O Antenna Deployment Safety Interlock
P Both Monitor & Control and
Deployment Safety Interlock
NOTE: Descriptions of the optional features are typically provided by separate appendices.
4
RC3000 Antenna Controller Chapter 1 Introduction
1.3 Theory of Operation
The RC3000 performs its functions via digital and analog electronic equipment interfaced to the antenna’s
motor drive and position feedback systems. This equipment is controlled through embedded software
algorithms run by the RC3000’s microcontroller. This section provides an overview of the equipment,
interfaces and major software functions.
1.3.1 Controller Description
The following figure is a block diagram showing the major components of the RC3000 :
LIQUID CRYSTAL DISPLAY (LCD). The 4 row by 40 column LCD provides the user interface for
monitoring the status of the RC3000 and for entering data.
KEYPAD. The 4 row by 4 column keypad allows the user to enter data and commands to the RC3000.
DIGITAL BOARD. The digital board is essentially a small computer containing a microcontroller,
memory, real-time clock and circuitry to monitor and drive the keypad and LCD. The digital board
performs the following major functions:
- monitors user inputs from the keypad
- displays information on the LCD screen according to controller mode, antenna status and user input
- monitors antenna drive status
- battery backs up non-volatile memory (configuration data, etc.) and the real-time clock
5
RC3000 Antenna Controller Chapter 1 Introduction
- performs communications between the microcontroller and the three (GPS, compass, remote control)
serial channels
- performs analog to digital conversion of drive position and signal strength inputs
- performs automatic antenna movement algorithms (locate, stow, recall, track, etc)
FEATURE BOARD. The feature board contains circuitry to implement many of the optional features of
the RC3000. The feature board provides the following major functions:
- signal drivers for PC remote control and navigation sensor serial communication
- circuitry for multiplexing signal strength indications from 1 of 3 sources
- circuitry for conditioning pulse based position feedback signals
- power transformation to supply required voltages to other modules
RF AUTOPEAK MODULE. This module accepts the output of an LNB (950-1450MHZ, -50 to –5dBm)
and generates a signal indicative of power across the band. This signal may be used for autopeak
operations.
ANALOG BOARD. The analog board contains circuitry to control the antenna motors and condition
antenna feedback signals. The analog board provides the following major functions:
- generation of azimuth and polarization limit indications based on sensed potentiometer feedback
- conditioning of elevation inclinometer input
- conditioning of azimuth stow and elevation up/down/stow limit switch inputs
- activation of relays (based on digital board control) to direct motor drive signals from the DC motor
control module.
DC MOTOR CONTROL MODULE. The solid state DC motor speed and reversing control module
contains circuitry for antenna motor regulation. This module provides:
- acceleration adjustment for smooth motor acceleration
- deceleration adjustment for ramp down time when motor speed lowered
- anti-plug instant reverse, solid state dynamic braking
- current limiting circuitry to protect the motor against overloads and demagnetization and to
limit inrush current during startup
- IR compensation to improve load regulation
POWER ENTRY MODULE. The power entry module allows the RC3000 to be configured for 115 or 230
VAC operation.
POWER TRANSFORMER. The power supply module transforms AC input voltage to a regulated DC
voltage for use by the digital and drive boards.
RESOLVER BOARD. To support mounts that use resolvers for position feedback, an optional resolver to
digital conversion board may be added to the baseline RC3000 hardware.
NOTE: Second Generation RC3000's (serial number > 2000) will have the circuitry of the analog board
and the feature board combined. Section 5.0 will contain the appropriate schematics for a particular
controller.
1.3.2 System Interface Requirements
The RC3000 is designed to interface with many different mobile antenna mounts. This manual attempts
to describe installation and operation in a manner applicable to most mounts.
The typical interfaces required for the RC3000 to perform all its automatic functions are described in
section 2.2 (Electrical Connections). Known differences to these interfaces and how they are
accommodated for a particular mount are described in appendix B (Mount Specific Data).
6
RC3000 Antenna Controller Chapter 1 Introduction
1.3.3 Operational Overview
The RC3000 allows easy antenna operation via its menu based user interface. The screen displayed to
the user is based on the current controller mode. Controller modes are divided into two major groups:
operational and programming (see mode map in section 3.1.1). The operational modes provide for the
normal operation of the antenna. The programming group provides for initial configuration of the
controller and will typically not be used on a day by day basis. The following example highlights the basic
modes of operation provided by the RC3000.
Operational Group Functions
MANUAL. In MANUAL mode the user may jog the antenna in azimuth, elevation and polarization. Upon
power up, the fluxgate compass and GPS receiver initialize and begin providing data.
AZIM: 0.0 STOW SIG: 50 MANUAL
ELEV: -67.5 STOW SAT:TELSTAR 402
POL: 0.0 SPD:FAST CST
<0-9>JOG ANTENNA <MODE>MENU 14:25:47
AUTOMATIC LOCATION OF A SATELLITE. In LOCATE mode, azimuth and elevation pointing angles
are automatically calculated based on position (lat/lon), heading and the selected satellite. Position may
be obtained automatically from the optional GPS, selected from a preset list of user defined positions or
entered manually. Heading may be automatically obtained from the optional fluxgate compass or entered
manually. The user selects which satellite to locate from either a preset user defined list of commonly
used satellites, a provided extensive list of satellites or by manually entering satellite data. The RC3000
checks that the calculated pointing solution is within the mount’s range of movement and prompts the
user to automatically position the antenna.
POS: 38°56N 94°44W 180.0 LOCATE
SAT:GALAXY 6 74.0W AZ:-31.1
EL: 40.0
<1>SELECT NEW SAT READY TO LOCATE
STORING SATELLITE LOCATION. After verifying the antenna is precisely on the satellite, the user may
STORE the satellite’s azimuth and elevation angles along with horizontal and vertical polarization data. If
the satellite has been identified as having an inclined orbit, the TRACK mode will be automatically
entered as described below.
SAT LON INCLIN BAND STORE
BRASIL A1 79.0 2 C
VERIFY SATELLITE DATA OK FOR STORING
1-CORRECT, 2-INCORRECT
RECALLING STORED SATELLITES. The user may quickly and precisely move between previously
STOREd satellites via RECALL mode.
RECALL
STORED SATELLITE: BRASIL A1
SELECT SAT(SCROLL UP/DOWN) <ENTER>
AUTOMATIC ANTENNA STOWING. From STOW mode, the user may ask for the antenna to be
automatically moved to the stow position.
AZIM: -42.5 ( 0.0) STOW
ELEV: 23.4 (-67.5)
MOVING TO (TARGET),<STOP> TO HALT MOTION
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RC3000 Antenna Controller Chapter 1 Introduction
Programming Group Functions
The programming group modes provide for initial configuration of the controller and also provide screens
to aid in maintenance and troubleshooting of the controller.
Configuration mode screens allow the user to customize and calibrate the operation of the RC3000 for
use with a particular mount. Note that most configuration items will be factory set for correct operation
with a particular mount.
REF_VOLT:2.50 OFF: 0.0 CONFIG-AZIM
CCW:180 CW:180 SF:76.35
SET REFERENCE VOLTAGE <2.00 - 3.00>
Maintenance mode screens allow the user to monitor sensor inputs and perform periodic maintenance
actions such as setting time and resetting drive errors.
SYSTEM:11/10/97 22:26:40 TIME
GPS UTC:11/10/97 22:26:40 ZONE:CST
DISPLAY:11/10/97 16:26:40 OFFSET:- 6
1-DATE 2-TIME 3-SYNCH 4-ZONE 5-OFFSET
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RC3000 Antenna Controller Chapter 1 Introduction
1.3.4 Antenna Pointing Solution
The position (latitude and longitude) of the mount and the longitude of a selected satellite are required to
calculate a pointing vector from the mount to the selected satellite.
Given the mount’s latitude and longitude and the pointing vector to the satellite, the RC3000 calculates
the elevation (with respect to local horizontal) required. Feedback from the inclinometer on the elevation
axis will be used to move the mount to the required elevation.
9
RC3000 Antenna Controller Chapter 1 Introduction
The azimuth portion of the pointing vector is calculated with respect to local true North. The fluxgate
compass is used to determine the heading of the centerline of azimuth travel and the required movement
in the azimuth axis is calculated.
In the above example a true heading of 135 degrees to the satellite has been calculated. Based on the
mount’s latitude, longitude and date, a local magnetic variation (see 1.3.8) of 10 degrees is calculated.
The compass senses a magnetic heading of 55 for the azimuth reference direction. Applying the
magnetic variation, this yields an apparent true heading of 45 degrees for the antenna reference
direction. An azimuth movement of 90 (135 – 45) degrees clockwise is therefore needed to point at the
satellite.
Since a position sensor on the azimuth axis is always active, the RC3000's default displayed azimuth
value is that of the antenna angle. Derived estimates of the magnetic and true heading of the mount may
be selected in the MANUAL (3.2.1) and LOCATE (3.2.2.3) modes.
10
RC3000 Antenna Controller Chapter 1 Introduction
1.3.5 Timekeeping
There are several versions of time (system, sidereal, referenced and GPS) discussed within this manual.
System time is maintained by the RC3000’s real time clock. The real-time clock is backed up by battery
so that system time is available as soon as the RC3000 powers up. The system time is used to calculate
sidereal time for maintaining track tables. Since satellite’s do not experience time shifts (such as from
Standard Time to Daylight Savings Time or when moving from one time zone to another), it is
recommended that system time not be modified while active track tables are present. If system time is
changed, the information stored in track tables for inclined orbit satellites will no longer be valid.
The RC3000’s system time is set to approximately Universal Coordinated Time (UTC) at the factory. It
will vary from UTC due to the tolerance of the real-time clock.
If the optional GPS receiver is installed, the RC3000 parses UTC from the data sent by the GPS receiver.
This data is only available when the GPS receiver is sufficiently locked on to GPS satellites to determine
UTC. The RC3000 allows the user to synchronize system time to the UTC reported by the GPS receiver.
The period of a satellite’s motion is one sidereal day (approximately 23 hours 56 minutes 4 seconds).
Entries in the track table for an inclined orbit satellite are stored at intervals of 1/48th of a sidereal day.
The RC3000 determines at what point in a sidereal day (with respect to the RC3000 reference) it is by
calculating how many sidereal days have passed from January 1, 1992 until the present system time.
In several screens the RC3000 displays a reference time. The user may designate a three letter
timezone designation and an hourly offset from system time. This allows the user to display local time or
some other reference time without modifying system time. If system time is maintained close to UTC, the
reference time displayed may be of use to operators for coordinating events.
See section 3.3.2.3 for details on time maintenance.
1.3.6 Drive System
The RC3000 implements several mechanisms for the driving and monitoring of the azimuth, elevation
and polarization axis.
Position Sensing and Limits
The RC3000 senses absolute axis position using feedback from various sensors (potentiometers,
resolvers, inclinometer for elevation, etc). The sensed voltage is scaled appropriately for the particular
mount. This sensed position is displayed in angular format.
For systems requiring very small movements for inclined orbit tracking, the RC3000 also supports pulse
feedback from the azimuth and elevation axis. Sensed pulses from the axis motor don’t provide an
absolute indication of position but allow for very precise relative movements.
The boresight of the antenna is displayed for the azimuth and elevation axis. In elevation, this angle is
with respect to the local horizontal. In azimuth, this angle is with respect to the centerline of azimuth
travel.
The following diagram shows a typical range of movement for mobile satellite antennas. Note that
elevation movement to the stow position is limited about a small range of azimuth movement in order to
ensure safe stowing of the antenna.
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RC3000 Antenna Controller Chapter 1 Introduction
In the azimuth axis, movement in one direction is disabled when clockwise and counterclockwise limit
switches are activated. There is also typically a region in the center of azimuth travel indicating that the
azimuth axis is in a position that will allow for moving the elevation axis down to the stow position.
In the elevation axis, there are typically three limit switches. The UP switch prevents further movement
up. The “DOWN” switch delimits the elevation the mount may not move further downward unless it has
been placed in the azimuth stow region. The STOW switch indicates when the mount has reached its
furthest down position which is typically where the dish is stowed for travel.
Jam and Runaway Sensing
The RC3000 continuously monitors the axis positions to detect incorrect movement of the mount. If an
axis has been commanded to move and the RC3000 does not detect movement within a prescribed time,
the controller will declare a “JAM” condition and not allow further movement in that axis until the condition
has been reset.
Similarly if the RC3000 senses movement in an axis when no movement should be occurring, the
RC3000 will declare a “RUNAWAY” condition. Like JAM, the RUNAWAY condition must be reset before
further movement in the axis may occur.
Anti-Reversal
In order to save wear on the drive motors, the RC3000 limits how fast an axis may reverse its direction.
This mechanism prevents a motor from instantly changing direction before coasting to a stop in the
original direction. This mechanism is also useful for correct counting of pulses. Since the RC3000
counts a pulse as being in the direction that the controller thinks the axis should be going, it is imperative
to stop the motor completely before moving in the opposite direction.
Automatic Movements
In order to provide smooth automatic movement to target positions, the RC3000 utilizes several
parameters to account for different mount characteristics.
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RC3000 Antenna Controller Chapter 1 Introduction
The Fast/Slow Transition parameter defines how far away from a target position the RC3000 will switch
from fast to slow motor speed. The Coast Range defines where the RC3000 will de-energize the motor
drive to allow the mount’s inertia to coast into the target position. The Max Error parameter defines how
close to the target position will be considered good enough.
Note that the DC motor control module in the RC3000 provides for smooth acceleration/deceleration, load
regulation and dynamic braking of the motors.
1.3.7 Polarization Control
The RC3000 calculates the required position and automatically moves the polarization axis as part of the
satellite LOCATE function. The following diagram shows the polarization axis sign convention used. The
diagram depicts looking at the arc of satellites from behind the antenna.
The RC3000 allows the user to specify the type of polarization axis mechanism present. If a circular
polarization scheme is present, no automatic movement of the polarization axis is performed. If a linear
polarization scheme is present, the RC3000 will calculate the theoretical position as a function of mount
latitude, mount longitude and satellite longitude.
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RC3000 Antenna Controller Chapter 1 Introduction
1.3.8 Magnetic Variation
In order to calculate satellite pointing solutions, the mount’s orientation with respect to true North must be
known. The RC3000 uses the fluxgate compass to measure the local horizontal component of the earth’s
magnetic field. The earth’s magnetic field is very irregular as shown in the following diagram from the
National Geophysical Data Center.
The magnetic field also changes slowly over time. The following table shows how the magnetic variation
for Washington D.C. has changed over the last 250 years.
YEAR MAGNETIC VARIATION
1750 -3.3
1800 -1.0
1850 -2.5
1900 -5.5
1950 -7.5
2000 -10.6
To calculate the local magnetic variation (difference between magnetic North and true North), the
RC3000 uses the International Geomagnetic Reference Field (IGRF) model. The IGRF is a mathematical
model of the earth’s magnetic field and how it is changing. The IGRF is based on world wide
observations and is updated every five years. The IGRF model cannot account for short term effects
such as magnetic storms, etc.
Local magnetic variation is calculated given the mount’s latitude, longitude and the current date. The
magnetic variation calculation cannot account for isolated local anomalies (typically less then a few
degrees). It also cannot account for local external effects (power lines, train tracks, etc). The autopeak
scan functions (3.2.2.3.2.3) used by the RC3000 attempt to compensate for the small heading calculation
errors that may occur at any particular location.
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RC3000 Antenna Controller Chapter 1 Introduction
1.3.9 System Performance
The performance achieved by the RC3000 in locating and tracking satellites is dependent on the
mechanical tolerances of the mount, the correctness of the installation and the accuracy of the various
sensors.
The largest source of error for the system is due to errors in determining the truck's magnetic heading.
Errors in heading primarily affect the accuracy of the antenna's calculated azimuth position. The flux gate
determines the magnetic heading by measuring the direction of the magnetic field at the sensor tower.
Problems arise because the earth's magnetic field can be distorted by ferrous metals (such as steel and
iron; aluminum is a non-ferrous metal) and man-made magnetic fields. These man-made fields can be
generated by electric motors, generators, and transformers, as well as those "worked into" the coach
body during manufacturing.
For the flux gate sensor, there are two unique categories of objects that distort the magnetic field in the
vicinity of the truck. Some of the distortion is due to objects and electrical devices on the truck itself. This
component of the distortion can be largely compensated for during system calibration.
The other component of the distortion is due to large metal objects and man-made magnetic fields around
the site where the truck is being operated. This component of the distortion varies as the truck moves
from one location to another, and it affects the accuracy of the calculated azimuth position. Environments
which typically produce the largest errors include railroad yards, areas around electrical substations, and
sites near structures containing large amounts of steel or iron, such as bridges or large buildings.
To date, the largest known azimuth error due to these interactions is less than 10 degrees. To help
alleviate this azimuth error, the Auto Peak feature scans an azimuth range about the target azimuth and
seeks the strongest signal. This feature is explained in full in section 3.2.2.3.
The RC3000 uses a 10 bit analog to digital converter for measuring voltages from azimuth, elevation and
polarization potentiometers as well as measuring signal strength inputs. In most cases this provides
adequate resolution but should be considered. For example, if the azimuth axis has 360 degrees of
travel, the resolution achieved is 360 / 1024 (approximately 0.35 degrees). This example highlights why
pulse or resolver sensors are used to make precise movements for inclined orbit tracking. The optional
resolver interface uses a 16 bit resolver to digital converter. This allows resolution of 0.0055 ( 360 /
65536) degrees.
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RC3000 Antenna Controller Chapter 1 Introduction
1.4 Specifications
Physical
Size 19.0 inches x 3.5 inches x 17.5 inches
Weight 19 lbs 13 lbs
Input Power
Fusing
Temperature -20C to +50C 0C to +50C
Humidity 35% to 85% (optional special-environmental kit available)
Antenna Drive
Azimuth/Elevation 12-36 VDC, 10 Amps max
Polarization 12-36 VDC, 10 Amps max 12 VDC, 1 Amp max
Electromechanical
Brakes (optional)
Waveguide/Switch
(optional) 24VDC 2Amps max or 115VAC 1 Amp max (specify on order)
Position Sense
Azimuth
Elevation
Polarization Potentiometer, 10-bit resolution standard; optional resolver, 16-bit resolution
Limit Switch Inputs
Locate Mode
Elevation Accuracy +0.2 degrees (typical)
Azimuth Accuracy +1.5 degrees (typical)
Polarization Accuracy +3 degrees (typical)
GPS Lockup Time 0 seconds (when configured for accessory powered GPS receiver)
VSAT Mode Single key-press-to-locate-operation for untrained operators
Autopeak Input
Modem Receive-Lock
Input TTL or contact closure, (optional non-invasive modem lock detector available)
Track Mode
Antenna Size 0.4 – 12.0 meters
Tracking Accuracy 0.1 to 3.0 dB selectable; mount dependent
Maximum Inclination 16 deg., standard
Tacking Modes
Signal-Strength Input -15VDC to +15VDC; 2Mohm input impedance, two channels
Non-volatile Memory
Backup Duracell DL2450
RC3000A RC3000B
115/230 VAC switchable 50/60Hz; 50W max
Idle;850W max Antenna Moving; optional
universal input
115 VAC, 8Amp Slow-Blow; 230 VAC,4
AMP Slow-Blow
115 OR 230 VAC 50/60Hz; 50W
max Idle;850W max Antenna
Moving
115VAC and 230VAC, 12 AMP Fast
Blow
90VDC (3/4 HP max) for 115VAC,90
or 180 VDC (1.5 HP max) for
230VAC input
28 VDC 300mA, or 115 VAC 1Amp
max(specify on order)
115 VAC 1Amp max (specify on
order)
Potentiometer, 10-bit resolution standard; optional single phase pulse sensors
(Reed, Hall-Effect, Optical); optional resolver, 16-bit resolution
Inclinometer, 10-bit resolution standard; optional single phase pulse sensors (Reed,
Hall-Effect, Optical); optional resolver, 16-bit resolution
Five- 12 VDC inputs, standard: EL Up, EL Down, EL Stow, AZ Stow, Pol Stow.Four
additional inputs optional, mount dependent
full L-Band power detection to find strongest signal.(configurable to AGC voltage or
Beacon receiver output -15VDC to +15VDC; 2Mohm input impedance, two
channels)
Step-Track, Memory-Track, Intelli-Searchtm , Program Track, optional Ephemeris
Track
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RC3000 Antenna Controller Chapter 2 Installation
2.0 INSTALLATION
Proper installation is important if the full capability and accuracy of the RC3000 is to be realized. The
procedures that follow will insure the optimum level of performance from all sensors and the system in
general.
Installation will be more efficient if each step in the physical installation and calibration be performed in
the order in which it appears in the following schedule. Each step is referenced to a particular section of
this manual, and should be checked off as it is completed. Coordination between the mount
manufacturer, vehicle integrator and end user is required. Some steps are applicable only if the tracking
or remote control options were purchased with the unit. The installation procedures are written to cover
the most common mount installations. Some steps are slightly different according to the type of mount
the RC3000 is interfacing to (see appendix B). Installation requires basic operational knowledge of the
RC3000. Please review chapter 3 for information on how to navigate the RC3000’s screens and how to
enter data.
SECTION ACTION COMPLETE
2.1 Equipment Mounting
2.1.1 RC3000 Antenna Controller
2.1.2 GPS Receiver
2.1.3 Fluxgate Compass
2.1.4 Inclinometer
2.2 Electrical Connections
2.2.1 Power Entry
2.2.2 Motor Drive
2.2.3 Drive Sense
2.2.4 Limit Switches
2.2.5 Signal Strength
2.2.6 Navigation Sensors
2.2.7 Accessories
2.2.8 RF Autopeak
2.2.9 Hand Held Remote
2.2.10 Pulse Sensors
2.2.11 PC Remote Control
2.2.12 Waveguide Switch
2.2.13 Resolver Inputs
2.3 Initial Configuration
2.3.1 Software Initialization
2.3.2 Elevation Calibration
2.3.3 Azimuth Calibration
2.3.4 Polarization Calibration
2.3.5 Fast/Slow Motor Speed
2.3.6 Pulse Sensor Checkout
2.3.7 Drive System Checkout
2.3.8 Navigation Sensor Communication
2.4 Final Calibration
2.4.1 Compass Calibration
2.4.2 Azimuth and Elevation Alignment
2.4.3 Signal Strength Adjustment
2.4.4 Pulse Scale Factors
2.4.5 Miscellaneous Adjustments
2.4.6 Mechanizing Automatic Locate
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RC3000 Antenna Controller Chapter 2 Installation
2.1 Equipment Mounting
This section describes the physical mounting requirements for the RC3000 and optional sensor units.
Wiring requirements are discussed in section 2.2.
2.1.1 RC3000 Antenna Controller
NOTE: The RC3000 unit should not be installed in the rack until the final step of the Initial
Configuration (section 2.3) because access to the interior of the unit may be necessary prior to
that procedure. The cables may be run through the chosen location in the rack and connected to
their respective components.
The RC3000 enclosure is a standard rack mount chassis that occupies two rack units (2U). The front
panel is mounted via four (4) 10-32 screws. Due to the length and weight of the RC3000, much strain
can be put on the faceplate, particularly in a mobile unit. To help alleviate stress on the front panel
mounting, additional mounting points accepting 10-32 and M4 screws are provided on each side, back
and bottom of the unit. The user may use any of these additional mounting points to provide support for
the RC3000 via strapping, shelving, etc. The additional mounting screws on the back of the unit may be
also used to provide strain relief for cabling.
CAUTION: support of the back of the RC3000 is a requirement. RCI’s warranty does not cover
repair to units with ripped faceplates.
The RC3000’s LCD is optimized for viewing from a 6 o’clock position. The optimum position to mount the
unit would therefore be above the operator’s eye level.
The following diagram shows the typical dimensions (in inches) of the RC3000. See appendix B for exact
dimensions of your controller. See section 5 for a detailed depiction of the side mounting holes.
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RC3000 Antenna Controller Chapter 2 Installation
2.1.2 GPS Receiver
The optional GPS receiver (RC3000GPS) should be mounted in a position (such as the truck’s roof)
where it has an unobstructed view of the horizon and sky. It should be mounted outside of the reflector
when in a stowed position, with the connector (on the underside) towards the cable’s entry point into the
truck. Care should be taken in the routing of the cable to avoid any problems.
The GPS receiver should be mounted at least three feet from other antennas and electrical generating
equipment. Strong RF interference from other sources may disrupt the GPS receiver’s signal reception.
Wiring of the GPS connector is discussed in section 2.2.6.
Recent RC3000s have been supplied with the GPS17 receiver model. The following diagram shows its
dimensions.
Earlier RC3000s were supplied with the GPS35 receiver model. The following diagram shows its
dimensions.
The GPS35 unit is supplied with 25 feet of cable. The GPS35 unit is supplied with a flange mounting
bracket as shown above. An optional marine mounting bracket is also provided.
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RC3000 Antenna Controller Chapter 2 Installation
2.1.3 Fluxgate Compass
The optional fluxgate compass unit (RC3000FG) should be placed on the roof of the vehicle away from
ferrous metals, electric motors, and any equipment that generates magnetic fields such as air
conditioners, generators, and traveling wave tube (TWT) amplifiers. Experience has shown that the
fluxgate performs best when mounted as high as possible on the vehicle. The fluxgate compass must be
mounted in an upright position.
Some mounts position the compass on the mount so that the compass may be lifted well above the top of
the vehicle. If the compass is attached to the mount, the compass configuration item (3.3.1.2.1) must be
set to the “antenna mounted” value.
The RC3000 uses the fluxgate to determine the true heading of the mount’s azimuth centerline (0.0
degrees azimuth). If the compass is not aligned in the direction of the azimuth centerline, that difference
must be described in the azimuth offset configuration item (3.3.1.2.3). Some operators prefer to mount
the compass pointing forward on the vehicle. If the mount faced rearward, an azimuth offset of 180
degrees would need to be input.
Refer to the drawing of the fluxgate enclosure to verify the proper orientation of the fluxgate. NOTE: An
unhoused version of the compass is available for use in a user-designed enclosure.
The Fluxgate Compass box may be either bracket mounted or flush mounted. Without the bracket it may
be attached to a flat surface by four 10-32 screws from inside or outside the box through the four corner
holes shown in the FRONT view diagram above. When using the bracket mount, it may be mounted with
four 1/4 inch bolts using the holes shown in the bottom view of the bracket in the above diagram. The
cable may be routed through either hole in the bracket. The circuit board may also be removed from the
housing or an unhoused model is available on order for custom installations.
The following method may be used to determine the best location for the compass.
Park the vehicle in a location that is away from large metal objects or sources of magnetic fields. NOTE:
for best results, the vehicle should be parked facing in an easterly or westerly direction. The
vehicle's generator should be running, as well as all electrical equipment on the vehicle that generates
magnetic fields.
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RC3000 Antenna Controller Chapter 2 Installation
Stand on the roof of the vehicle with a standard magnetic compass. Slowly lower the compass to the
proposed fluxgate mounting location on the vehicle without changing the orientation (or heading) of the
compass body. If the needle of the compass swings as the compass is lowered to the mounting location,
it is due to distortion of the earth's magnetic field by ferrous metals on the vehicle, or magnetic fields
generated by the vehicle.
The fluxgate should be mounted in the location where the needle of the compass experiences the
minimum amount of swing as the compass is lowered to the proposed mounting location.
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RC3000 Antenna Controller Chapter 2 Installation
2.1.4 Electronic Clinometer
The electronic clinometer (also referred to as the inclinometer) should be positioned on the mount
structure in an orientation that allows the inclinometer’s linear range of movement to rotate through the
antenna’s RF boresight operational range.
Determining the correct orientation of the inclinometer requires knowledge of the mount’s mechanical
structure and the antenna’s RF offset. Typically the mount manufacturer will place the inclinometer in the
correct position on the mount. See appendix B for the correct orientation for a particular mount.
The elevation position sense circuit of the RC3000 is designed to interface to the Lucas/Schaevitz
AccuStar model 0211 1002-000 or 0211 1102-000 inclinometers. The inclinometer’s position reference is
marked on the body of the inclinometer. The inclinometer should be mounted such that the body of the
inclinometer is rotated CW (as viewed by an observer looking at the front of the inclinometer) as the
antenna’s elevation angle increases. The inclinometer must also be oriented properly on the antenna
mount.
To describe the orientation of the inclinometer, the term ‘elevation offset angle’ needs to be defined.
Elevation offset angle is defined as the antenna’s RF elevation pointing angle (relative to horizontal) when
a straight edge oriented vertically across the face of the antenna reflector (reflector top to bottom) is
plumb. The inclinometer should be oriented so that, when the antenna reflector is plumb, the reference
mark is deflected CCW (from the vertical position) by an amount equal to the 35 degrees minus the
‘elevation offset angle’. If the inclinometer is attached as described the sensor will operate in its most
accurate region for elevation look angles up to 80 degrees.
The inclinometer mounting flange allows for some adjustment of the device’s rotational orientation. The
mounting position selected for the inclinometer should allow for adjustment of the inclinometer’s
orientation. The inclinometer should be mounted in a location such that it is protected somewhat from
blowing rain.
See section 2.2.3 for wiring of the inclinometer.
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