Vertex Standard 7122B, 7133B user guide

CG-1045

REV D

APRIL 2000

OPERATION AND MAINTENANCE MANUAL

FOR

MODEL 7122B/7133B ANTENNA CONTROL UNIT

INCLUDING UNITS WITH

3 PHASE POLARIZATION MOTORS

Controls & Structures Division

1915 Harrison Road

Longview, Texas 75604

CAUTIONARY NOTICE

Although 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, checking out, operating, and servicing this equipment.
Care should be taken to avoid electrical shock, whether the hazard is caused by
design or malfunction.

The manufacturer is specifically not liable for any damage or injury arising from failure
to follow the instructions contained in this manual or failure to exercise due care and
caution in the installation, operation, checkout, and service of this equipment.

PROPRIETARY NOTICE

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

WARNING

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

PLEASE READ THE FOLLOWING PRECAUTIONS

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.

The installation, operation, maintenance, and service of this equipment involves risks
both to personnel and equipment and must be performed only by qualified personnel
exercising due care. Vertex Communications Corporation shall not be responsible for
injury or damage resulting from improper procedures or from the use of 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.

WARNING

ALWAYS DISCONNECT POWER BEFORE OPENING COVERS,
DOORS, ENCLOSURES, GATES, 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.

Do not remove, short-circuit, or tamper with interlock switches on access covers, doors,
enclosures, gates, panels, or shields. Keep away from live circuits. Know your equipment
and don't take chances.

WARNING

IN CASE OF EMERGENCY BE SURE THAT POWER IS DIS­CONNECTED.

TABLE OF CONTENTS

PARAGRAPH

NO.

1.1 The Purpose of the 7122B/7133B Manual 1-1

1.2 General Information about the 7122B/7133B ACU 1-1

1.2.1 System Hardware 1-1

1.2.1.1 7122B/7133B ACU 1-1

1.2.1.2 7122B/7133B OU Drive Cabinet 1-2

2.0 Installation and Initial Set-Up 2-1

2.1 Overview 2-1

2.2 Mechanical Installation 2-1

2.2.1 Antenna Mounted Components 2-1

2.2.2 Installing the 7122B/7133B ACU 2-1

2.3 System Cabling 2-2

2.4 Display Offset Adjustment 2-4

3.0 Operation 3-1

3.1 7122B/7133B ACU 3-1

TITLE PAGE NO.

3.2 7122B/7133B OU 3-1

3.2.1 7122B/7133B OU Controls 3-2

4.0 Acceptance Test Procedure 4-1

4.1 Preliminary Information 4-1

4.2.1 Maintenance Mode 4-1

4.2.2 Remote Mode 4-2

5.0 Recommended Spares 5-1

6.0 Engineering Drawings 6-1

Appendix A Acronyms and Abbreviations A-1

Appendix B Technical Support B-1

INTRODUCTION

1.0 INTRODUCTION

1.1 The Purpose of the 7122B/7133B Manual

The purpose of this manual is to provide the user with the information necessary to
install and operate the Vertex Model 7122B/7133B Antenna Control Unit (ACU). This
manual contains only the information related to the 7122B/7133B ACU and contains
only limited information about the antenna structure or other equipment peripheral to
the 7122B/7133B.

1.2 General Information about the 7122B/7133B ACU

The 7122B/7133B controller series is designed for applications requiring high
reliability and low cost. The readout system provides 0.02E resolution, using
brushless 2.5 KHz resolvers. The motor drive circuit provides the operator with single
speed, real-time drive control.

The 7133B controls the elevation and azimuth movement of the antenna and the
polarization movement of the feed horn. The 7122B controls only the elevation and
azimuth movement of the antenna. Otherwise, the 7122B and the 7133B are
identical.

1.2.1 System Hardware

The 7122B/7133B controller consists of the following subsystems:

Model 7122B/7133B ACU

·

Model 7122B/7133B OU

·

Resolver

·

7122 and 7133 are Vertex's basic system model numbers. ACU is the acronym for
antenna control unit, which refers to the 19-inch rack-mountable unit used in the
shelter or other antenna control room. OU is the acronym for outside unit, which
refers to the weather-proof cabinet typically installed near the antenna.

The ACU interfaces with starters and motors for elevation, azimuth, and polarization
positioning of the antenna. The elevation, azimuth, and polarization limit interfaces
are normally closed switches that open upon engagement.

1.2.1.1 7122B/7133B ACU

The primary components of the 7122B/7133B ACU are:

Front Panel

·

1 - 1

INTRODUCTION

Power Supply

·

Resolver/Digital PC Board

·

Display Board Assembly

·

Binary/BCD Board Assembly

·

Switch PC Board Assembly

·

The front panel contains the POWER ON/OFF switch that controls the power to the
circuit boards on the 7122B/7133B ACU.

The 7122/7133 Controller Resolver to Digital PC Board Assembly (800029) converts
the analog output of the elevation, azimuth, and polarization resolvers to digital.

The 7122/7133 A, B, and C Antenna Control Unit Front PC Board (800026) contains
seven-segment displays and associated circuitry for display of the elevation, azimuth,
and polarization positions of the antenna.

The Front Switch PC Board (800032 - 7133B; 800050 - 7122B) contains three­position momentary on/off switches that control the elevation, azimuth, and
polarization movement of the antenna.

1.2.1.2 7122B/7133B OU Drive Cabinet

The 7122B/7133B OU consist of the following major components:

Swing-Out Panel

·

MAIN POWER Circuit Breaker

·

EMERGENCY STOP Switch

·

24 VDC Power Supply

·

Reversing Starters

·

Relay PC Board

·

The swing-out panel allows the operator to control antenna movement from the
proximity of the antenna.

The MAIN POWER circuit breaker controls the main power and the power to the OU
cabinet and the limit switches.

The EMERGENCY STOP switch, when pressed, removes power from the drive
motors.

The 24 VDC power supply provides operating voltage to the 7122B/7133B OU
antenna drive relay circuit board.

1 - 2

INSTALLATION

2.0 INSTALLATION AND INITIAL SET-UP

WARNING
Always disconnect power before opening covers, doors,
enclosures, gates, panels, or shields. Never make internal
adjustments or perform maintenance or service when alone
or fatigued. Main power connections and grounding should
be performed by qualified personnel. Keep away from live
circuits; know your equipment and don't take chances. In
case of emergency, be sure to disconnect power before
touching equipment or personnel in contact with the
equipment.

2.1 Overview

This section of the manual provides the information necessary for the installation and
initial set-up of the 7122B/7133B ACU.

The system installation and set-up instructions are presented in the following general
order.

Mechanical Installation

·

System Cabling

·

Power-Up and Set-Up

·

2.2 Mechanical Installation

2.2.1 Antenna Mounted Components

Proper and complete installation of the 7122B/7133B outside unit, motors, resolvers,
and limit switches is imperative for safe and accurate system operation. Refer to the
mechanical drawings supplied in the drawing package separate from this manual for
mechanical interface details and complete this phase of installation first.

2.2.2 Installing the 7122B/7133B ACU

Using four No. 10 screws, mount the 7122B/7133B ACU inside a standard 19-inch
EIA rack. No added support is necessary.

2.3 System Cabling

Refer to Figure 2-1 for a block diagram of the 7122B/7133B Antenna Control
System. The following paragraphs describe the cabling and list the connections for
the 7122B/7133B. Cables must be connected from the antenna to the OU, from the
OU to the 7122B/7133B ACU, and from the antenna resolvers to the ACU. Be sure
the cables are connected correctly and securely because proper functioning of the
system during power-up is important for the protection of the equipment and for
timely completion of the installation.

2 - 1

INSTALLATION

Figure 2-1. 7133B Antenna Control System Block Diagram

2 - 2

Table 2-1 shows the connections between the ACU and the OU.

TABLE 2-1. 7122B/7133B ACU CONNECTIONS TO 7122B/7133B OU

ACU, J8 PIN NO. FUNCTION OU TERMINAL STRIP

1 AZ CW COMMAND 1

2 AZ COMMON 2

3 AZ CCW COMMAND 3

4 EL UP COMMAND 4

5 EL COMMON 5

6 EL DOWN COMMAND 6

7 POL CW COMMAND 7

8 POL COMMON 8

INSTALLATION

9 POL CCW COMMAND 9

10 AZ CW LIMIT 10

11 AZ CCW LIMIT 11

12 EL UP LIMIT 12

13 EL DOWN LIMIT 13

14 POL CW LIMIT 14

15 POL CCW LIMIT 15

16 EMERGENCY STOP 16

17 GROUND 17

18 GROUND 18

19 +24V 19

20 +24V 20

2 - 3

INSTALLATION

The resolvers are connected as shown in Table 2-2.

TABLE 2-2. 7122B/7133B ACU RESOLVER

CONNECTIONS

PIN NO. COLOR FUNCTION

2Red/WhiteR1

8 Yellow/White R2

9RedS1

5BlueS2

4 Black S3

3 Yellow S4

1,6,7 SHIELD

After installation is complete, if one or more of the resolvers is counting backward or
if electrical zero is almost 180E out of phase, perform one of the following tasks.

1. Reverse S2 and S4 (SIN) leads to reverse direction without shifting
electrical zero.

2. Reverse S1 and S3 (COS) leads to shift electrical zero and
reverse direction.

3. Reverse R1 and R2 (REF) leads to shift electrical zero 180°. Direction
remains the same.

2.4 Display Offset Adjustment

The elevation, azimuth, and polarization readout angle may be adjusted with the
digital switches inside the 7122B/7133B ACU using the following procedures.

1. Remove the top cover and locate the six 8-bit digital DIP switches (four on the
7122B) on the binary/BCD board, mounted to the left side of the chassis.

2. The offset switches are labeled AZ (S1 and S2), EL (S3 and S4), and POL (S5
and S6). Switches 1 and 2 are not used on DIP switches S1, S3, and S5.
Switch 3 on DIP switches S1, S3, and S5 controls the most significant bit
(180°) and switch 8 or DIP switches S2, S4, and S6 controls the least
significant bit (0.022°). Set the switches to obtain the desired display angles.

3. To intentionally blank an axis, set the 16 switches as follows:
(MSB)1010101010101010(LSB)

4. Replace the top cover.

2 - 4

OPERATION

3.0 OPERATION

3.1 7122B/7133B ACU

The front panel controls of the 7122B/7133B ACU are shown in the following table.

7122B/7133B ACU CONTROLS AND INDICATORS

CONTROL OR INDICATOR FUNCTION

POWER ON/OFF Switch Provides power for the ACU.

AZIMUTH, POLARIZATION, and
ELEVATION Indicator

LIMITS AZ CW/CCW, POL CW/CCW,
and EL UP/EL DOWN Indicators

EMERGENCY Indicator LED illuminates if the Emergency Stop Switch is

AZ CW/CCW Switch Momentary switch provides jog control of the

POL CW/CCW Switch Momentary switch provides jog control of the

EL UP/DOWN Switch Momentary switch provides jog control of the

7-segment displays indicate the azimuth,
polarization, and elevation angle of the antenna.

LEDs illuminate if the respective limit switch is
activated.

activated.

antenna azimuth drive motor.

polarization drive motor (feed tube rotation).

antenna elevation drive motor.

3.2 7122B/7133B OU

The 7122B/7133B OU is a self-contained motor drive unit that can operate the
antenna drive motor without using the 7122B/7133B ACU. However, the
7122B/7133B OU has no display to show the antenna position.

3 - 1

OPERATION

3.2.1 7122B/7133B OU Controls

The following table shows the functions of the controls on the 7122B/7133B OU.

7122B/7133B OU CONTROLS

CONTROL FUNCTION

MAIN POWER Circuit Breaker Controls power to the elevation, azimuth, and

polarization motors, the limit switches, and the
7122B/7133B ACU.

MAINT/REMOTE Switch In the REMOTE position only the 7122B/7133B

ACU controls antenna movement. In the MAINT
position only the 7122B/7133B OU controls
antenna movement.

EMERGENCY STOP Switch Located on the side of the OU. The push button

must be pulled outward before the ACU or OU
can be used to control the movement of the
antenna. Pressing this button removes the
control voltage to the motor contactor.

EL UP/DOWN Switch Momentary contact switch that controls the

elevation movement of the antenna.

POL CW/CCW Switch Momentary contact switch that controls the

polarization movement of the feed tube.

AZ CW/CCW Switch Momentary contact switch that controls the

azimuth movement of the antenna.

3 - 2

ATP

4.0 ACCEPTANCE TEST PROCEDURE

4.1 Preliminary Information

This test procedure is intended to serve as the final proof of performance document
for the 7122B/7133B ACU, subsequent to field installation and set-up. Prior to the
performance of these tests, the system must have been installed and adjusted as
described in Section 2.0 of this manual. Motor rotation direction should be normalized
and limit stops should be set.

4.2.1 Maintenance Mode

1. On the 7122B/7133B OU set the MAIN POWER circuit
breaker to ON. _______(Check)

2. Verify that the EMERGENCY STOP button is in the out
position. _______(Check)

3. Set the MAINT/REMOTE switch to MAINT. _______(Check)

4. Using the EL UP/DOWN switch, drive the antenna and
verify correct directional movement of the antenna. _______(Check)

5. Using the EL UP/DOWN switch, drive the antenna UP
and verify that the limit switch stops the movement of
the antenna. _______(Check)

6. Using the EL UP/DOWN switch, drive the antenna DOWN
and verify that the limit switch stops the movement of the
antenna. _______(Check)

7. Using the AZ CW/CCW switch, drive the antenna and
verify correct directional movement of the antenna. _______(Check)

8. Using the AZ CW/CCW switch, drive the antenna CW
and verify that the limit switch stops the movement of
the antenna. _______(Check)

9. Using the AZ CW/CCW switch, drive the antenna CCW
and verify that the limit switch stops the movement of
the antenna. _______(Check)

4-1

10. Using the POL CW/CCW switch, drive the feed horn and
verify correct directional movement of the feed horn. _______(Check)

11. Using the POL CW/CCW switch, drive the feed horn CW
and verify that the limit switch stops the movement of the
feed horn. _______(Check)

12. Using the POL CW/CCW switch, drive the feed horn CCW
and verify that the limit switch stops the movement of the
feed horn. _______(Check)

4.2.2 Remote Mode

1. Set the MAINT/REMOTE switch on the 7122B/7133B OU
to REMOTE. _______(Check)

ATP

2. From the 7122B/7133B ACU drive the antenna in elevation
and verify correct directional movement of the antenna. _______(Check)

3. Drive the antenna UP and verify that the limit switch
stops the movement of the antenna. _______(Check)

4. Drive the antenna DOWN and verify that the limit switch
stops the movement of the antenna. _______(Check)

5. From the 7122B/7133B ACU drive the antenna in
azimuth and verify correct directional movement of
the antenna. _______(Check)

6. Drive the antenna CW and verify that the limit switch
stops the movement of the antenna. _______(Check)

7. Drive the antenna CCW and verify that the limit switch
stops the movement of the antenna. _______(Check)

8. From the 7122B/7133B ACU drive the feed horn and verify
correct directional movement of the feed horn. _______(Check)

9. Drive the feed horn CW and verify that the limit switch
stops the movement of the feed horn. _______(Check)

10. Drive the feed horn CCW and verify that the limit switch
stops the movement of the feed horn. _______(Check)

4-2

ATP

4-3

5.0 RECOMMENDED SPARES

The following tables list the recommended spares for the 7122B/7133B ACU
and Drive Cabinet.

7122B/7133B ACU RECOMMENDED SPARES

QTY DESCRIPTION VERTEX PART NO.

1 Circuit Breaker, 1A CCB007

SPARES

1

1 PCB, Display BBB035

1 PCB, Resolver/Digital BBB056

1 PCB, Binary/BCD BBB057

1 PCB, Switch BBB042

QTY DESCRIPTION VERTEX PART NO.

1 Circuit Breaker, 3-Pole, 20A CCB074

1 Circuit Breaker, 3-Pole, 6A CCB092

1 Circuit Breaker, 3-Pole, 2A CCB081

1 Circuit Breaker, 1-Pole, 1A CCB076

1 Reversing Contactor CPC056

Power Supply +5, -12 VDC

7122B/7133B DRIVE UNIT RECOMMENDED SPARES

CPS004

1 Relay, Thermal Overload 4.0A BRL125

1 Relay, Thermal Overload 1.6A BRL126

1 Power Supply, 24 VDC CPS002

1 PCB, Relay 800057-01

1 PCB, Switch 800057-02

5-1

ENGINEERING DRAWINGS

6.0 ENGINEERING DRAWINGS

The following list shows the engineering drawings provided in this section.

200000 Binary-BCD Board Schematic

201023 Drive Unit (3 PH POL) 208-240 VAC 3 Phase, 7133B Custom

201027 Antenna Drive Unit 208-220-240 VAC 3 Phase, 7133B Series 2

800020 7122B Outside Unit Top Assembly and Wiring Diagram

800026 7122/7133 A, B, and C Antenna Control Unit Front PC Board Layout

800029 7122/7133 Controller Resolver to Digital PC Board Assembly

800032 Model 7133A/7133B Front Switch PC Board Layouts and Assemblies

800034 Model 7122/7133 Antenna Controller Binary to BCD PC Board Assembly

800050 Model 7122A/7122B Front Switch PC Board Layouts and Assemblies

800057 Model 7133B OU Drive Unit Relay and Switch PC Board Assemblies

800151 Model 7122B Drive OU Relay and Switch PC Board Assemblies

800153 Model 7122B Antenna Control Unit Assembly and Wiring Diagram

800455 Model 7133B Antenna Control Unit 120/220-240 VAC, 1PH STD

800631 Antenna Drive Unit 380-415 VAC, 3 Phase Model 7133B

6-1

ACRONYMS/ABBREVIATIONS

APPENDIX A - ACRONYMS AND ABBREVIATIONS

The following is a list of acronyms and abbreviations that are used by Vertex
Control Systems and may appear in this manual.

A Amperes
AC Alternating Current
ACS Antenna Control System
ACU Antenna Control Unit
A/D Analog-to-Digital
ADU Antenna Drive Unit
AGC Automatic Gain Control
AOS Acquisition of Star
ASCII American Standard Code for Information Interchange
ASSY Assembly
AST Adaptive Steptrack
AZ Azimuth

BCD Binary Coded Decimal
BDC Block Downconverter
BIT Built-In Test
BW Bandwidth

CCW Counterclockwise
CFE Customer-Furnished Equipment
COM Common
CPU Central Processing Unit
CR Carriage return
CRLF Carriage return/line feed
CW Clockwise

dB Decibel
dBm Decibel referred to 1 milliwatt
DC Direct Current
deg Degrees
DMM Digital Multimeter
DOS Disk Operating System

EIA Electronic Industries Association
EIC Encoder Input Circuit
EL Elevation
EPROM Erasable Programmable Read-Only Memory
E STOP Emergency stop

A - 1

ACRONYMS/ABBREVIATIONS

FLT Fault
FSM Finite State Machine
FWD Forward

GHz Gigahertz
GND ground

HB High Byte
HP horsepower
Hz Hertz

I/O Input/Output
IC Integrated Circuit
IEC International Electrotechnical Commission
IEE Institute of Electrical Engineers
IEEE Institute of Electrical and Electronic Engineers
IF Intermediate Frequency
ISIO Intelligent Serial Input/Output

km Kilometer

LB Low Byte
LED Light-Emitting Diode
LNA Low Noise Amplifier
LOS Loss of Signal (Loss of Star)
LSB Least Significant Bit
LSI Large Scale Integration
LT Long-term

M Meter
M&C Monitor and Control
mA Milliamperes
mb Multibody (propagator)
MHz Megahertz
ms Millisecond

N/A Not applicable
NEC National Electrical Code
NEMA National Electrical Manufactures Association
NORAD North American Air Defense Command
NVRAM Nonvolatile Read-Only Memory

O&M Operations and Maintenance
OPT Orbit Prediction Tracking

A - 2

PC Printed circuit
PCB Printed-Circuit Board
PH Phase
PLL Phase-Lock Loss
PMCU Portable Maintenance Control Unit
POL Polarization
p-p Peak-to-peak
PROG Program
PROM Programmable Read-Only Memory

RAM Random Access Memory
RC Resistance-capacitance
RDC Resolver-to-Digital Converter
REV Reverse
RF Radio Frequency
RFI Radio Frequency Interference
RMS Root mean square
ROM Read-Only Memory
rpm Revolutions per minute

ACRONYMS/ABBREVIATIONS

sec Second
SPST Single-Pole Single-Throw
ST Short-term
STD Standard

2b Two-body (propagator)
TBT Tracking Band Translator
TBU Test Bed Unit
TEE True Equinox and Equator
TT&C Telemetry, Tracking, and Control

UTC Coordinated Universal Time

VVolts

A - 3

TECHNICAL SUPPORT

APPENDIX B - TECHNICAL SUPPORT

If you have any questions or problems that are not addressed by the manual, there
are several ways to contact our technical support team.

1. Phone us at [phone].

2. Email us at [e-mail].

3. Make copies of the following Technical Inquiry form and fax us your questions

at [phone].

4. Contact us on our web site at www.vcsd.com.

B-1

Technical Inquiry FAX [phone]

CUSTOMER NAME: SITE:

CONTACT: PHONE: EXT:

FAX: EMAIL:

Tech Support

EQUIPMENT: (INCLUDE MODEL, NAME, AND SERIAL NUMBER OF ALL PERTINENT EQUIPMENT)

1. Model:

2. Model:

3. Model:

4. Model:

OTHER EQUIPMENT

TECHNICAL QUESTION/PROBLEM:

S/N:
_________________
_________________
_________________
_________________

VCSD RESPONSE:

VCSD TROUBLESHOOTER DATE TIME REF. NO.

B-2