Page 1 HiSeasNet Maintenance Visit Report Ship Visited: R/V Oceanus Ship Location/Port: Woods Hole, MA Date(s) of work: 15, 16 September 2009 Work performed by: Karl Kapusta Visit Purpose: General Maintenance & Repair The Oceanus had been reporting tracking problems during its last cruise, as well as DAC-PCU communication errors and “Remote Not Responding” errors. These problems indicate a loss of communications between the DAC and the PCU caused by either a component or cable problem. Replacement FSK multiplexors were sent to the ship but not installed prior to the Maintenance Visit. Also, a recent antenna inspection by the crew had identified some missing hardware on the antenna, (nuts, bolts, etc.), which needed to be replaced. This visit was a combination of troubleshooting, repair and maintenance.
Transcript
Page 1
HiSeasNet Maintenance Visit Report
Ship Visited: R/V Oceanus Ship Location/Port: Woods Hole, MA Date(s) of work: 15, 16 September 2009 Work performed by: Karl Kapusta Visit Purpose: General Maintenance & Repair The Oceanus had been reporting tracking problems during its last cruise, as well as DAC-PCU communication errors and “Remote Not Responding” errors. These problems indicate a loss of communications between the DAC and the PCU caused by either a component or cable problem. Replacement FSK multiplexors were sent to the ship but not installed prior to the Maintenance Visit. Also, a recent antenna inspection by the crew had identified some missing hardware on the antenna, (nuts, bolts, etc.), which needed to be replaced. This visit was a combination of troubleshooting, repair and maintenance.
Page 2
Maintenance Checklist Antenna Equipment (ignore SeaTel/Ship-specific points with * for fixed antennas)
Initials Action Notes/Discussion
KK Inspect or change air conditioner filter Complete
KK Verify air conditioner is in working order, repair as needed N/A No Air Conditioner is installed
KK Confirm/Set final air conditioner temperature set point (85 deg F)
N/A
KK Take photo of dome interior or main antenna support N/A
KK Take photo of rack gear front Complete
KK Take photo of rack gear rear Complete
KK Perform SeaTel or Vertex service bulletin upgrades/repairs Complete – N/A
KK Inspect reflector, repair as needed Complete – N/A
KK Inspect antenna equipment/frame/cowls for water, rust, or damage, repair as needed
Complete Antenna is in good condition
KK Lube/grease/treat any joints as necessary Complete – N/A
KK Inspect antenna equipment and wiring harness for loose cables, repair as needed
Complete All cables tight and secure
KK Sweep antenna through entire Az and El ranges Complete
KK Verify and record reasonable search limits or safety stops for given location and satellite, adjust as needed
Complete N/A
KK Inspect cabling and connectors behind and around rack gear, repair as needed
Complete All cables are tight and secure
KK Take photo of radome exterior * Complete
KK Visual inspection of radome (cracks, abrasions, caulk, leaks, excessive grime, etc.), repair as needed *
Complete Radome is in good condition
with no visible damage
KK Visual inspection of radome base, legs, and connection to ship (rust, warping, etc.), repair as needed *
Complete Base is in good condition with
no rust or warping
KK Check antenna balance, adjust as needed * Complete Balance is good – no adjustment
required
KK Inspect antenna equipment/frame for loose weights and hardware, repair as needed *
Complete All weights are tight and secure
KK Verify power level to pedestal/motors * Complete
KK Verify pedestal breaker works, repair as needed * Complete
KK Verify acceptable antenna/controller Power-On Self Test (POST) *
Complete
Page 3
Initials Action Notes/Discussion
KK Record DAC/controller parameters * Complete See attached list
KK Verify DAC parameters are accessible, correct, and saved * Complete
KK Verify that GPS inputs to DAC function (if GPS is operational) *
Complete Lat & Long are supplied by GPS
antenna mounted on antenna
KK Verify that gyro inputs to DAC function (if gyro is operational) *
Complete
KK Verify correct conscan or dishscan settings, adjust as needed *
Complete
KK Verify reasonable blackout zone, adjust as needed * Complete None programmed
KK Check Az/El trim values, correct as needed to get longitude search close *
Complete
KK Locate spares kit. Verify completeness of the kit, note missing parts. *
Complete
KK Upgrade SeaTel/controller firmware with maintenance releases as necessary *
Complete Not Required
KK Verify dish will sweep full elevation range of motion (-15 to +115 degrees) physically *
Complete
KK Verify dish will sweep full elevation pointing (0-90 degrees) when commanded by DAC *
Complete
KK Verify dish will do a full azimuth sweep physically at the lowest physical elevation *
Complete
KK Verify dish will do a full azimuth sweep at the lowest pointed elevation when commanded by the DAC *
Complete
KK Verify dish frame lines up with and will safely bump against all rubber stops should it reach the end of its range of motion *
Complete
KK Locate and test RS-422/RS-232 adapter used with converter, modify pinouts so it is not needed, or verify that it is not needed as is. Note status. *
Complete
KK Install newest version of RemDAC software and leave a copy with the techs *
Complete
Page 4
Codan RF Equipment
Initials Action Notes/Discussion
KK Take photo of converter panel Complete
KK Verify converter is not in an undue alarm state Complete
KK Verify power levels at power supply (48 VDC, and 110 VAC). Record VDC and VAC
Complete VAC = 116from ship’s UPS
system VDC = 48.3 VDC from
Comtech modem
KK Inspect RF coax cables and connectors, repair as needed Complete – all connecters are in good condition
KK Verify amplifier cooling fan functions Complete
KK Verify amplifier is not being overdriven, correct as needed Complete
KK Locate and test DB-9/MIL serial cable that talks directly to converter
Complete
KK Locate spare LNB Complete LNB is stored on ship with other
spare parts
KK Record settings (include serial number and wattage for amp, serial number for converter, and amplifier output type)
Complete BUC s/n 7740132F0007
Comtech Modem Equipment
Initials Action Notes/Discussion
KK Verify settings are accessible, correct, and saved Complete
KK Verify modem locks on the correct signal, adjust as needed Complete
KK Visually inspect transmit signal directly for clean signal Complete
KK Verify expected EbNo values for given location Complete Eb/No approx. 6.8 dB
KK Record settings Complete
KK Upgrade firmware as necessary (at least Rev 1.30) Complete 570L version 1.6.4
KK Replace 5V PSU power cable if needed Complete – N/A
Page 5
Cisco Router Equipment
Initials Action Notes/Discussion
KK Verify cables and connectors are snug and screwed in, repair as needed
Complete
KK Verify serial cable is a CAB-530MT with Comtech Cisco adapter and modem is in RS-422 mode
Complete
KK Verify that green connect light on serial card is lit when modem is locked up
Complete
KK Verify router survives a power cycle and can route traffic within 15 minutes of turning on while connected. Notify techs that they may want to save router settings!!
Complete
Rack Equipment
Initials Action Notes/Discussion
KK Inspect rack conditions for proper rack gear cooling, lighting, wiring, etc. (Earth station: Verify lights and A/C work)
Complete
KK Check and record rack air conditioner set point Complete No Air Conditioner thermostat available – room is very cool
Overall
Initials Action Notes/Discussion
KK Take photos of ship/dome placement Complete
KK Check with ship techs/crew for overall impression of equipment performance and possible problem areas
Complete Tracking issues and DAC
Communications errors were addressed
SEE NOTES
KK Locate spares kit (with help from techs) and verify all SeaTel spares and one LNA exist. Note discrepancies.
Complete LNB is stored with other spare
parts
KK Verify spectrum analyzer shows proper picture of Tx and Rx carriers
Complete
KK Comment on or correct previous maintenance report issues that were pointed out
Complete
Page 6
General Notes
There were four main issues addressed during this visit. They included:
1. Reported tracking problems
2. Higher than normal DAC PCU communications errors
3. Low AGC and Threshold levels after DAC power cycle
4. Missing antenna hardware.
The Oceanus crew had been reporting tracking problems for the previous few weeks. Replacement FSK multiplexors had been sent to the ship, but not installed prior to the Maintenance Visit.
On-site, no obvious problems were found with the existing multiplexors. However, all four units were replaced with spares. The original units were sent back to Seatel for evaluation
A higher than normal rate of DAC communication errors were being logged by the DAC.
These errors were possibly contributing to the tracking problems, and the issue was investigated.
The source of the errors was found to be the ship’s Gyro compass supplying the DAC with the ship’s Heading information. While the cause of the errors was not completely understood, it is believed that the unit was causing interference with the DA PCU communications.
It should be noted that the DAC was receiving the correct Heading information from the unit. No correlation between these errors and antenna tracking problems were found
The ship’s crew were continuing the troubleshooting and were looking into changing the Heading input to a different unit
A DAC software issue was found during testing by the crew before the maintenance visit. When the DAC is power cycled and the antenna pedestal is not, the DAC will report abnormally low AGC (<1000) and Threshold (<1000) values. If the DAC is then reset using the front panel reset button, the correct values are restored.
Page 7
This condition was previously found on the DAC 2202 units, and the issue was resolved with a software update. However, this DAC is a 2200 model, and it has the latest version of software for both the main unit functions, (motherboard), and the DVB turner card. The problem has been reported to Seatel and they are working on a software update. Until Seatel can provide new software, there is no other solution but to use the front panel reset button when the issue occurs.
A recent antenna inspection by the ship’s technical personnel found some missing mounting bolts and spacers. The missing parts were replaced using parts from Seatel and stainless steel hardware supplied by the ship’s crew. Loctite was used on all the replacement hardware. Also, the entire antenna assembly was checked for any additional loose or missing parts. None were found.
The antenna Transmit waveguide path includes a section of flex waveguide composed of
an inner copper waveguide and an outer rubberized, weatherproof cover. One seam, where the outer cover is sealed to the waveguide flange, had separated, leaving a small space. This space was sealed using weatherproof latex caulk. The integrity of the waveguide is not compromised and the crack has been sealed.
has built and installed a signal cable that provides a direct correlation between the Comtech modem RX lock and the tracking of the DAC. Basically, the cable sends a signal to the DAC when the modem has a Receive lock on the satellite signal.
Page 8
RV Oceanus
15, 16 September 2009 Radome Placement & Exterior - 1
Page 9
RV Oceanus
15, 16 September 2009 Radome Placement and Exterior - 2
Page 10
RV Oceanus
15, 16 September 2009 Radome Placement
Page 11
RV Oceanus
15, 16 September 2009 Radome Interior – 1
Note replaced cable support standoff hardware on Cross-Level Gear
Page 12
RV Oceanus
15, 16 September 2009 Radome Interior 2
Note Allen Head replacement bolt that holds reflector support arm to antenna frame and replacement bolt attaching aluminum side plate to reflector support arm directly above it
Page 13
RV Oceanus
15, 16 September 2009 Radome Interior 3
Note replacement bolt and spacer between reflector support arm and aluminum side plate
Page 14
RV Oceanus
15, 16 September 2009 Radome Interior 4
Note Flexible waveguide section. Crack in seam on left side where outer rubber coating meets
flange was repaired using latex caulk. No structural damage was found in waveguide
NOTE:
Page 15
RV Oceanus
15, 16 September 2009 Below Decks Equipment 1
Front View of Equipment Rack
Page 16
RV Oceanus
15, 16 September 2009 Below Decks Equipment 2
Side View of Equipment Rack showing Base Plate with FSK Multiplexors and IFL Cable
connections
Page 17
RV Oceanus
15, 16 September 2009 Below Decks Equipment 3
Equipment Room with Equipment rack on left side of photo
Page 18
Final Equipment Configuration/Settings
HiSeasNet Satellite Equipment Configuration
Ship: R/V Oceanus Date: 15, 16 September,
2009
Location: Woods Hole, MA Satellite: Satmex 5
116.8 degrees W
Unit Setting Description Setting
Display Setting Value Notes
SeaTel Digital Antenna Controller (DAC)
Model DAC-2200 Antenna system is a model 6006-23 (8 Watt
Ku-Band amplifier) Serial Number Firmware Ver 5.20 PCU ver 2.45b AGC (Normal, On signal) 1937 Value when antenna is
peaked up on signal AGC (Normal, Off Signal) 1010 Value of noise when
antenna is not on satellite Latitude LAT 41 N Woods Hole, MA Longitude LON 70 W Woods Hole, MA Heading HDG 243.6 Woods Hole, MA Satellite SAT 116.8 W Atlantic satellite Threshold THRS 1208 Antenna Controller locked
to hub carrier Intermediate Frequency L-Band
Frequency 1050 MHz Shore-to-ship signal
frequency to track BAUD 20000 Tone OFF Used for RX systems only Volt RHCP – N/A Used for RX only systems FEC AUTO Sets DAC Tuner card to
SCPC mode NID 0000 Used for RX only systems
to identify video carriers Azimuth AZ 237.7 Woods Hole, MA Elevation EL 23.2 Woods Hole, MA Relative Azimuth REL 352.8 Relative to bow of the
ship
Page 19
Elevation Trim EL TRIM -0023 In 1/10 of a degree Azimuth Trim AZ TRIM 0016 In 1/10 of a degree Auto Threshold AUTO THRESH 0240 In counts Elevation Step Size EL STEP SIZE 0000 Azimuth Step Size AZ STEP SIZE 0000 Step Integral STEP
Sweep Increment SWEEP INC 0000 Factory Use only System Type SYSTEM TYPE 0069 Controller set for auto
search upon power failure or system reset
Gyro Type GYRO TYPE 0002 Set for NMEA information string from ship's
gyrocompass Polarization Angle Type POLANG TYPE 0072 Set for Automatic - used
with Linear Polarized feeds
Polarization Offset POL OFFSET 0040 Adjusted with Loral for best cross-pol performance
Polarization Scale POL SCALE 0090 N/A - not used on circular polarized antennas
Azimuth Blackout Limit 1 AZ LIMIT 1 0000 Does not transmit or try to search in the blackout
zone Azimuth Blackout Limit 2 AZ LIMIT 2 0000 Does not transmit or try
to search in the blackout zone
Azimuth Blackout Limit 1 AZ LIMIT 3 0000 Does not transmit or try to search in the blackout
zone Azimuth Blackout Limit 2 AZ LIMIT 4 0000 Does not transmit or try
to search in the blackout zone
Azimuth Blackout Limit 1 AZ LIMIT 5 0000 Does not transmit or try to search in the blackout
zone Azimuth Blackout Limit 2 AZ LIMIT 6 0000 Does not transmit or try
to search in the blackout zone
Transmit Polarity TX POLARITY 0004
Page 20
PCU System Type N0 0022 CL Torque Motor Setting N1 0075 LV Torque Motor Setting N2 0065 AZ Torque Motor Setting N3 0051 CL Trim Setting N4 0011 LV Trim Setting N5 0223 Home Flag Offset N6 0191 Dishscan System Setting N7 0025 Dishscan ON Satellite Reference ON
Codan Power Amplifier (PA) SSPA Serial Number BUC Serial number Converter Serial Number N/A No converter required Transmit Frequency TX Freq. 14436.3950 Converted transmit
center frequency Transmit Output Power TX Output
PWR 35.7 dBm Actual TX Output Power
from the BUC Receive Attenuation Rx Atten 0 dB N/A – RX level controlled
by LNB LNB Fault Control Faults: LNB N/A SSPA Fault Control Faults: Fan N/A Fan Fault Control Faults: SSPA N/A IF Impedance Impedance N/A PA State ON Transmit On (RS232) ON Transmit On (RS485) ON Transmit On (FSK) ON Transmit Default Last State Compensation Freq. 14436 IF Comp Freq. 1014 LO Frequency Local Oscl 15450 TX Alarm Threshold 0.0 Burst PWR Threshold 0.0 Serial Interface 9600,8,N,1 Packet Protocol Packet
Protocol NDSATCOM
Packet Address Packet Addr. 1 Redundancy Mode NON Redundancy On/Off Line N/A
Page 21
Comtech CDM-570L Satellite Modem
(In CONFIG menu)
Serial Number Firmware Modem Firmware Average Eb/No 6.8 dBm Energy/Bit over noise
TX RF Frequency 14436.2150 MHz Ship TX frequency to Hub Station
TX Output State RX-TX Inhibit TX Output PWR Level Manual, -28 dBm ¾ QPSK TX Scrambling TX:SCRAM ON TX Clocking Mode TX:CLK INTERNAL Modem set to Internal
clocking TX Spectrum Inverted TX Data Sense Normal RX FEC TPC RX Modulation RX:MOD QPSK RX Code Rate RX: Rate 3/4 RX Data Rate RX:DATA 256.00 kbps RX Symbol Rate RX: Sym 0170.667 sym RX IF Frequency RX:IF 1386.0650 MHz RX RF Frequency RX:RF 12136.0650 MHz RX Demod Acquisition RX: Acq +/- 30 KHz RX Descrambling ON RX Buffer RX: Buf Disabled RX Spectrum Normal RX Data Sense Normal RX Eb/No Alarm Point 2.0 dB Frequency Reference Internal 10 MHz TX FIFO Alarm MASKED G.703 – BPV Alarm MASKED TX AIS Alarm MASKED AGC Alarm ACTIVE
Page 22
Eb/No Alarm MASKED RX AIS Alarm MASKED Buffer Alarm MASKED Reference Alarm MASKED BUC Alarm MASKED LNB Alarm ACTIVE BUC M&C FSK Comms ON BUC RF Output ON BUC FSK Address 01 BUC DC Power ON BUC 10 MHz Reference ON BUC Current Alarm – Upper Limit
3500 mA
BUC Current Alarm – Lower Limit
1000mA
BUC LO Frequency 15450 MHz Attach BUC Alarm to TX ? NO BUC Frequency Mix High Side LNB DC Supply OFF LNB 10 MHz Reference OFF LNB Current Alarm – Upper Limit
600 mA
LNB Current Alarm – Lower Limit
010 mA
LNB LO Frequency 10750 MHz Attach LNB Alarm to RX ? NO LNB Frequency Mix Low Side Remote Control Local
