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COBHAM Sea Tel 09 Series Upgrade Procedure
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COBHAM Sea Tel 09 Series Upgrade Procedure

COBHAM Sea Tel 09 Series Upgrade Procedure

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Summary of Contents for COBHAM Sea Tel 09 Series

  • Page 2: Tools Required

    Upgrade P rocedure, x x 09 M K 2 1.1. Upgrade Procedure, xx09 MK2 electronics Upgrading an 09 Pedestal to MK2 electronics can be accomplished using the 132196 Upgrade Kit and the following procedure. Please read this entire procedure before beginning work. 1.1.1.

  • Page 3: Buc Power Supply

    Upgrade P rocedure, x x 09 M K 2 1.1.4. Overview of the Upgrade In very simple terms, you will: • Remove the current Pedestal Control Unit (PCU), replace it with the MK2 PCU, Install a short harness adapter and re-connect the cables. •...
  • Page 4 Upgrade P rocedure, x x 09 M K 2 Using the cutters, cut the large cable tie on the power cord connector and disconnect the power cord. Using the small flat blade screwdriver, remove the PCU M&C connector. Using the 5/16” (8mm) open end wrench remove the two coax cables.
  • Page 5 Upgrade P rocedure, x x 09 M K 2 Using the 3/16” (5mm) Allen wrench remove the 4 cap head screws that mount the PCU to the side pan. Retain these for later use. Install the 131298-5 adapter pigtail to the 121485 feed harness (removed from the “Polang”...
  • Page 6 Upgrade P rocedure, x x 09 M K 2 Back of dish Apply Loctite 242 to the four cap head screws removed in the previous step. 3 SMA connectors 10. Mount the MK2 PCU using the four cap head screws. With the dish up at zenith (90°...
  • Page 7 Upgrade P rocedure, x x 09 M K 2 Remove the two Phillips screws that mount the existing GPS to its bracket. Clean the upper surface of the bracket thoroughly with a lint free cloth and acetone solvent. Apply the sticky side of the double stick tape (124077-5 provided in the upgrade kit) to the bracket.
  • Page 8 Upgrade P rocedure, x x 09 M K 2 1.1.8. MK2 PCU connections Connect all the cables to the MK2 PCU. Connect the Orange mini coax (this is the Cross-Pol coax which will route to the LNB on the feed) SMA connector to the “NC J1”...
  • Page 9 Upgrade P rocedure, x x 09 M K 2 Install the power cable into the power receptacle and install a 7” cable tie through the P-clamp and around the cable to prevent it from loosening during vibration. Install the Motor Drive to the MDE harness to the “Motor Control”...
  • Page 10 Upgrade P rocedure, x x 09 M K 2 1.1.9. Routing the Cross-Pol and Co-Pol coaxes Route, and terminate, the Cross-Pol and Co-Pol coaxes. Route the Orange and Yellow coaxes to the bridge with the other harness cables while omitting the Cross-Pol and Co-Pol coaxes (both have black shrink tubing at the connectors).
  • Page 11 Upgrade P rocedure, x x 09 M K 2 Continue cutting and replacing the ties to fininsh routing the Yellow coax across the remainder of the bridge. If your system includes a waveguide diplexer and Co-Pol LNB, route the Yellow coax to the LNB and tie the coax at several convenient points.

  • Page 12: Replacing The Motor Driver Enclosure (Mde)

    Upgrade P rocedure, x x 09 M K 2 1.1.10. Replacing the Motor Driver Enclosure (MDE) The following procedure for replacing the MDE. Remove and mark the 5 connectors, one at a time, using the small flat blade screwdriver and the felt tip marker.
  • Page 13 Upgrade P rocedure, x x 09 M K 2 Using the 10mm open end wrench, remove the 4 10mm nuts (two on top and two on the bottom of the MDE) that mount the MDE to the pedestal. Remove the original MDE. Apply loctite 242 to the four threaded mounting bolts and mount the MK2 MDE using the four...

  • Page 14: Antenna Initialization

    Upgrade P rocedure, x x 09 M K 2 Coarse balance configuration drawings CURRENT Description Configuration Configuration BALANCE WEIGHT KIT, EL & CL, 4009-11 130621-1 131921-1 BALANCE WEIGHT KIT, EL & CL, 4009-17 130338-1 131922-1 BALANCE WEIGHT KIT, EL & CL, 4009-23 130586-1 BALANCE WEIGHT KIT, EL &...

  • Page 15: Balancing The Antenna

    Upgrade P rocedure, x x 09 M K 2 If any of these steps fail, or the ACU reports model "xx09", re-configure the PCU as described in the Maintenance section of the Dealer Technical Manual. If initialization still fails, this indicates a drive or sensor problem, refer to the Troubleshooting section.
  • Page 16 Upgrade P rocedure, x x 09 M K 2 A normal trace display will be ± 1 divisions from the red reference line while under calm sea conditions and with DishScan Drive turned off. See example below The Cross Level display will decrease (plots below red line) as the antenna requires drive to the left and increase (plots above red line) as the antenna requires to the right.
  • Page 17 Upgrade P rocedure, x x 09 M K 2 The Azimuth display should decrease (plots below red line) as the antenna is driven CCW and increase (plots above red line) as the antenna is rotated CW. 1.1.16. Testing the Antenna Conduct the Functional Testing as described in the 131118 Series 09 Scheduled Inspections Record manual.
  • Page 18 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 131057-1 ENCLOSURE ASS'Y, PCU, 09G2, 3 CH, 232 1 EA 131227-1 ENCLOSURE ASS'Y, MOTOR DRIVER, 09G2 1 EA 131381-1 GPS ANTENNA, SERIAL, AAA001005-G, NAV 1 EA 131298-5 X2 HARNESS ASS'Y, REFLECTOR, 09 UPGRADE 1 EA 113303-10...
  • Page 19 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 6 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 1 EA 108519-1 G WEIGHT, TRIM 4.0 OZ 1 EA 108519-3 G WEIGHT, TRIM 6.0 OZ 2 EA 115420-2 G TRIM WEIGHT, 10 X 3 X 3/8 IN 1 EA 126279-3 A2 NUT, 1 5/8 UNISTRUT, 1/4-20, W/SPRING...
  • Page 20 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 5 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 2 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 2 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 2 EA 126279-3 A2 NUT, 1 5/8 UNISTRUT, 1/4-20, W/SPRING 1 EA 114586-540...
  • Page 21 REVISION HISTORY REV ECO# DATE DESCRIPTION ITEM 1 WAS QTY 4; ITEM 3 WAS QTY 1; ITEM 4 WAS 108519-2; ITEM 10 WAS QTY 4; ITEM 51 WAS QTY 2; ITEM 52 WAS QTY 2; 6769 07/10/09 K.D.H. ITEM 58 WAS QTY 7; ADDED ITEMS 5 & 59; RELEASED TO PRODUCTION, WAS X1. ITEM 1 WAS QTY 2.
  • Page 22 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 10 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 3 EA 108519-3 G WEIGHT, TRIM 6.0 OZ 1 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 1 EA 108519-1 G WEIGHT, TRIM 4.0 OZ 2 EA 115420-2...
  • Page 23 REVISION HISTORY REV ECO# DATE DESCRIPTION 7194 03/30/10 RELEASED TO PRODUCTION. WAS REVISION X1. 05/14/10 CHANGED TITLE. DETAIL C EQUIPMENT FRAME & ANTENNA ASSEMBLIES SHOWN FOR REFERENCE ONLY DETAIL A DRAWN BY: UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. X.X = .050 DRAWN DATE: 02/19/10 X.XX = .020...
  • Page 24 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 108519-2 G WEIGHT, TRIM 5.0 OZ 1 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 2 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 4 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 2 EA 126279-3...
  • Page 25 This drawing and specifications are the property FINISH: APPROVED DATE: EL & CL, 4009-17 of Cobham PLC. Neither this document, the information, or the specifications disclosed shall be reproduced or transferred in whole or in part for any purpose without the specific written...
  • Page 26 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 2 EA 115420-2 G TRIM WEIGHT, 10 X 3 X 3/8 IN 10 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 3 EA 108519-3 G WEIGHT, TRIM 6.0 OZ 1 EA 108519-1 G WEIGHT, TRIM 4.0 OZ 1 EA 114586-538...
  • Page 27 REVISION HISTORY REV ECO# DATE DESCRIPTION 7194 03/30/10 RELEASED TO PRODUCTION. WAS REVISION X1. 05/14/10 CHANGED TITLE. PARTIAL EQUIPEMENT FRAME & ANTENNA ASSEMBLIES SHOWN FOR REFERENCE ONLY NOTES: UNLESS OTHERWISE SPECIFIED 1. APPLY ADHESIVE PER SEATEL SPEC. 121730. 2. TORQUE THREADED FASTENERS PER SEATEL SPEC.
  • Page 28 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 3 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 1 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 3 EA 108519-3 G WEIGHT, TRIM 6.0 OZ...
  • Page 30 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 2 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 1 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 1 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 2 EA 126279-3 A2 NUT, 1 5/8 UNISTRUT, 1/4-20, W/SPRING...
  • Page 31 REVISION HISTORY REV ECO# DATE DESCRIPTION 6771 07/08/09 RELEASED TO PRODUCTION. NO PRIOR REVISION. 6854 09/11/09 REPOSITIONED WEIGHTS WITHIN ASSEMBLY. ADDED NOTE 5. DETAIL B (BRIDGE NOT SHOWN FOR CLARITY) DRAWN BY: UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. X.X = .050 NOTES: UNLESS OTHERWISE SPECIFIED DRAWN DATE: DETAIL A...
  • Page 32 Upgrade P rocedure, x x 09 M K 2 134094-1 BALANCE WEIGHT POSITIONS, 4009-23/33 MK2 UPGRADE Refer to BOM 132624-1 UPGRADE KIT, BALANCE WEIGHTS, XX09, MK2 Document No Page 32 of 64 132622 Rev B Form # 117140-B...
  • Page 33 REVISION HISTORY REV ECO# DATE DESCRIPTION 8332 02/04/11 RELEASED TO PRODUCTION. NO PRIOR REVISION. 4009-33, MK2 UPGRADE SHOWN 4009-33, MK2 UPGRADE SHOWN NOTES: UNLESS OTHERWISE SPECIFIED 1. APPLY ADHESIVE PER SEATEL SPEC. 121730. 2. TORQUE THREADED FASTENERS PER SEATEL SPEC. 122305. 3.
  • Page 34 4009-23, MK2 UPGRADE SHOWN 4009-23, MK2 UPGRADE SHOWN 58 58 DETAIL F SCALE 1 : 4 52 58 58 10 DETAIL E DETAIL D SIZE SCALE: DRAWING NUMBER 134094 2 OF 2 SHEET NUMBER...
  • Page 35 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 126026 AZ COUNTER WEIGHT MOD 2 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 2 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 4 EA 114586-542 SCREW, HEX HD, 1/4-20 x 1-3/4, S.S.
  • Page 36 Upgrade P rocedure, x x 09 M K 2 DWG Pg 1 - NOT AVAILABLE YET Document No Page 36 of 64 132622 Rev B Form # 117140-B...
  • Page 37 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 2 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 1 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 3 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 3 EA 114586-540 SCREW, HEX HD, 1/4-20 x 1-1/4, S.S.
  • Page 38 This drawing and specifications are the property APPROVED DATE: FINISH: EL & CL, 5009-11, MK2 of Cobham PLC. Neither this document, the information, or the specifications disclosed shall be reproduced or transferred in whole or in part for any purpose without the specific written...
  • Page 39 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 126026 AZ COUNTER WEIGHT MOD 2 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 2 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 4 EA 114586-542 SCREW, HEX HD, 1/4-20 x 1-3/4, S.S.
  • Page 40 REVISION HISTORY REV ECO# DATE DESCRIPTION 04/15/09 RELEASE TO PRODUCTION, NO PRIOR REVISION. EQUIPMENT FRAME SHOWN FOR REFERENCE ONLY NOTES: UNLESS OTHERWISE SPECIFIED 1. APPLY ADHESIVE PER SEATEL SPEC. 121730. 2. TORQUE THREADED FASTENERS PER SEATEL SPEC. 122305. WEIGHTS SHOWN ARE A STARTING POINT ONLY.
  • Page 41 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 2 EA 118560 WEIGHT, TRIM, 1 x 3.38 x 3, 2.8 LBS 2 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 2 EA 114586-540 SCREW, HEX HD, 1/4-20 x 1-1/4, S.S. 4 EA 114586-542 SCREW, HEX HD, 1/4-20 x 1-3/4, S.S.
  • Page 42 This drawing and specifications are the property APPROVED DATE: FINISH: EL & CL, 5009-17, MK2 of Cobham PLC. Neither this document, the information, or the specifications disclosed shall be reproduced or transferred in whole or in part for any purpose without the specific written...
  • Page 43 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 5 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 2 EA 114586-541 SCREW, HEX HD, 1/4-20 x 1-1/2, S.S. 2 EA 114586-542 SCREW, HEX HD, 1/4-20 x 1-3/4, S.S.
  • Page 45 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 4 EA 108519-4 G WEIGHT, TRIM 7.0 OZ 1 EA 114586-540 SCREW, HEX HD, 1/4-20 x 1-1/4, S.S. 2 EA 114586-541 SCREW, HEX HD, 1/4-20 x 1-1/2, S.S. 5 EA 114580-029 WASHER, FLAT, 1/4, S.S.
  • Page 47 Upgrade P rocedure, x x 09 M K 2 BALANCE WEIGHT POSITIONS, 5009-23/33 MK2 UPGRADE - NOT AVAILABLE YET Refer to BOM 132624-1 UPGRADE KIT, BALANCE WEIGHTS, XX09, MK2 Document No Page 47 of 64 132622 Rev B Form # 117140-B...
  • Page 48 Upgrade P rocedure, x x 09 M K 2 DWG Pg 1 - NOT AVAILABLE YET Document No Page 48 of 64 132622 Rev B Form # 117140-B...
  • Page 49 Upgrade P rocedure, x x 09 M K 2 DWG Pg 1 - NOT AVAILABLE YET Document No Page 49 of 64 132622 Rev B Form # 117140-B...
  • Page 50 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 108894-2 G1 WEIGHT, TRIM, 3/8 X 3 X 10, 3.19 LBS 3 EA 108894-3 G1 WEIGHT, TRIM, 1/2 X 3 X 10, 4.25 LBS 1 EA 108894-4 G1 WEIGHT, TRIM, 1/4 X 3 X 10, 2.12 LBS 1 EA 108519-1...
  • Page 52 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 108894-3 G1 WEIGHT, TRIM, 1/2 X 3 X 10, 4.25 LBS 1 EA 108894-4 G1 WEIGHT, TRIM, 1/4 X 3 X 10, 2.12 LBS 1 EA 108894-2 G1 WEIGHT, TRIM, 3/8 X 3 X 10, 3.19 LBS 2 EA 118560...
  • Page 53 REVISION HISTORY REV ECO# DATE DESCRIPTION 7252 05/10/10 RELEASED TO PRODUCTION. WAS REVISION X1. 58 59 DETAIL A EQUIPMENT FRAME AND MOUNTING ASSEMBLIES ARE SHOWN FOR REFERENCE ONLY. DRAWN BY: UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. X.X = .050 58 10 DRAWN DATE: 04/13/10...
  • Page 54 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 108894-2 G1 WEIGHT, TRIM, 3/8 X 3 X 10, 3.19 LBS 2 EA 108894-3 G1 WEIGHT, TRIM, 1/2 X 3 X 10, 4.25 LBS 2 EA 108894-4 G1 WEIGHT, TRIM, 1/4 X 3 X 10, 2.12 LBS 1 EA 108519-4...
  • Page 56 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 1 EA 108894-3 G1 WEIGHT, TRIM, 1/2 X 3 X 10, 4.25 LBS 1 EA 108894-4 G1 WEIGHT, TRIM, 1/4 X 3 X 10, 2.12 LBS 1 EA 108894-2 G1 WEIGHT, TRIM, 3/8 X 3 X 10, 3.19 LBS 2 EA 118560...
  • Page 57 REVISION HISTORY REV ECO# DATE DESCRIPTION 7252 05/10/10 RELEASED TO PRODUCTION. WAS REVISION X1. 58 59 DETAIL A EQUIPMENT FRAME AND MOUNTING ASSEMBLIES ARE SHOWN FOR REFERENCE ONLY. DRAWN BY: UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. X.X = .050 DRAWN DATE: 04/16/10 X.XX = .020...
  • Page 58 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 2 EA 108894-3 G1 WEIGHT, TRIM, 1/2 X 3 X 10, 4.25 LBS 1 EA 112573-2 WEIGHT, TRIM, 1/2 x 2.75 x 3, 1.17 LB 1 EA 108894-1 G1 WEIGHT, TRIM, 1/4 X 1 X 10, .71 LBS 2 EA 108519-4 G WEIGHT, TRIM 7.0 OZ...
  • Page 60 SINGLE LEVEL MFG BILL OF MATERIAL FIND QTY PART NO REV DESCRIPTION REFERENCE DESIGNATOR 2 EA 108894-3 G1 WEIGHT, TRIM, 1/2 X 3 X 10, 4.25 LBS 1 EA 108894-1 G1 WEIGHT, TRIM, 1/4 X 1 X 10, .71 LBS 1 EA 108519-3 G WEIGHT, TRIM 6.0 OZ 1 EA 108519-4...
  • Page 62 Upgrade P rocedure, x x 09 M K 2 BALANCE WEIGHT POSITIONS, 6009-23/33 MK2 UPGRADE - NOT AVAILABLE YET Refer to BOM 132624-1 UPGRADE KIT, BALANCE WEIGHTS, XX09, MK2 Document No Page 62 of 64 132622 Rev B Form # 117140-B...
  • Page 63 Upgrade P rocedure, x x 09 M K 2 DWG Pg 1 - NOT AVAILABLE YET Document No Page 63 of 64 132622 Rev B Form # 117140-B...
  • Page 64 Upgrade P rocedure, x x 09 M K 2 DWG Pg 1 - NOT AVAILABLE YET Document No Page 64 of 64 132622 Rev B Form # 117140-B...

This manual is also suitable for:

Sea tel 4009-11Sea tel 4009-17Sea tel 4009-23Sea tel 4009-33Sea tel 5009-11Sea tel 5009-17 ... Show all