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Intertronic ITA-0210-02 Maintenance And Repair Manual

Njit 2.1m antenna
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NJIT 2.1m ANTENNA
MAINTENANCE AND REPAIR MANUAL
Model Number: ITA-0210-02
Serial Number: 001
Document Number: 1100-006
Revision: B
th
Date: October 15
2013
©InterTronic Solutions Inc. 2013

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Summary of Contents for Intertronic ITA-0210-02

  • Page 1 NJIT 2.1m ANTENNA MAINTENANCE AND REPAIR MANUAL Model Number: ITA-0210-02 Serial Number: 001 Document Number: 1100-006 Revision: B Date: October 15 2013 ©InterTronic Solutions Inc. 2013...
  • Page 2 - 2 - Revision table Revision Date Description of Changes 15/10/2013 Updated to reflect current design, added troubleshooting information 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611 - 2 -...

  • Page 3: Table Of Contents

    - 3 - Table of Contents Revision table ............................- 2 - Introduction ............................- 5 - Safety Information ..........................- 5 - System Overview ............................ - 6 - Axis Encoders ............................- 6 - Motors ..............................- 6 - Elevation Jack ............................
  • Page 4 - 4 - Error Codes and Descriptions ......................- 20 - Drive Error Codes and Status Words ..................... - 20 - Component Replacement ........................- 25 - Drive Module Replacement ......................- 25 - SM-I/O Plus and SM-Universal Encoder Plus ................. - 25 - SM-Ethernet ..........................

  • Page 5: Introduction

    - 5 - Introduction This manual covers the maintenance of the antenna system, control cabinet and related components. Maintenance and repairs should only be performed by qualified technicians familiar with the system and components. Adjustment of drive parameters and setup can cause unwanted sudden movement of the antenna.

  • Page 6: System Overview

    - 6 - System Overview Axis Encoders The elevation and azimuth axes are each fitted with Heidenhain ECN 225 absolute angle encoders. These absolute encoders have an accuracy of 10 arc seconds and provide 25 bit communications resolution using the EnDat2.2 version 02 serial data interface. The encoders interface with the drives using SM-Universal Encoder Plus modules.

  • Page 7: Elevation Limit Switches

    - 7 - Elevation Limit Switches There are two Honeywell NC type limit switches mounted inside the turning head. One switch provides low elevation limit and the other high elevation limit. They are accessible by removing the turning head cover plate. When operating in Normal Mode, it should never be possible to trip these switches. If a limit switch does occur, it should be thoroughly investigated.

  • Page 8: Drives

    - 8 - Drives Each axis motor is controlled by its own drive. They are SP1201 drives from Emerson Control Techniques and interface directly with the motors and encoders used. They operate on 200-240VAC 3-phase or single-phase with a max output of 5.2A. Each inverter drive contains three expansion slots for various solutions modules.

  • Page 9: Navigating Drive Menus With The Keypad

    - 9 - Navigating Drive Menus with the Keypad 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611 - 9 -...
  • Page 10 - 10 - 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611 - 10 -...
  • Page 11 - 11 - 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611 - 11 -...

  • Page 12: Modifying And Saving Drive Parameters

    - 12 - Modifying and Saving Drive Parameters To modify a drive parameter:  Use the keypad to navigate to the desired menu and parameter  Press the black Mode button to enter the parameter edit mode  The parameter value will flash ...

  • Page 13: Regular Maintenance - To Be Performed Every 6 Months

    - 13 - Regular Maintenance – To be Performed Every 6 Months Conduit and Wiring Visual Inspection  Inspect all cable conduits for cracking, perforation or chafing. Inspect cable conduit end fittings to insure they are tightly connected.  Inspect all wiring for cracking, perforation or chafing. Make sure cables are not under excessive strain and appropriate strain relief is provided.

  • Page 14: Emergency Stop Test

    - 14 -  Turn REMOTE/OFF/STANDBY/OPERATE switch to STANDBY and then to OPERATE  Using the Hand Controller, move the reflector through its entire range of motion, both in azimuth and elevation. Verify that the antenna stops when it has tripped a limit switch. It should then only be possible to move away from the limit until the limit switch is released.

  • Page 15: Slew Ring Bearing Greasing

    - 15 - Slew Ring Bearing Greasing Remove upper pedestal access plate Using a grease gun attached to the grease nipple on the inner ring of the slew ring, insert new grease while rotating the reflector across its entire azimuth range. Take care not to trip the limit switches with the grease gun hose.
  • Page 16 - 16 - Wipe off old grease from pinion gear. Apply fresh coat of grease around entire pinion. Rotate the reflector as necessary. ** USE OPEN GEAR EXTREME PRESSURE AND TEMPERATURE GREASE ** Rotate reflector across its entire azimuth range so that new grease is spread across the external teeth of the slew ring.

  • Page 17: Troubleshooting

    - 17 - Troubleshooting Any unexpected system behaviour or error must be investigated. There are various ways of finding useful clues and diagnosing any issues. CTScope is also a powerful tool used to trend and trace various drive parameters. It can be very helpful in tracking down any potential issues. The first step is to look at the diagnostics page in the ACI for any trip codes or error statuses.
  • Page 18 - 18 - Any current drive trip will be displayed on the drive keypad. Refer to the appropriate Control Techniques documentation for information on specific trips. Some of the most common drive trips are detailed in the Antenna Controller Software Manual. Here is a list of the most useful parameters to aid with troubleshooting Parameter Description...

  • Page 19: List Of Possible Status Faults

    - 19 - List of Possible Status Faults OFFLINE: SM-Applications Plus module not properly seated in drive, failure of 24VDC supply or supply wiring to drive, faulty wiring between nodes, CTNet setup parameters have been changed TRIPPED: 3-phase power contactor to drive is open resulting in an Under Voltage UU trip, drive is tripped by an E-Stop button resulting in an External Et Trip JAM: Motor is trying to drive against brake (i.e.

  • Page 20: Error Codes And Descriptions

    - 20 - Error Codes and Descriptions Below is a list of error codes, the drive parameters they are stored in and a brief description of the error. This list is intended to aid in basic trouble shooting and to indicate which parameters to look at to diagnose any errors.
  • Page 21 - 21 - #10.09: 1 = Drive Output is at Current Limit #10.10: 1 = Regenerating #10.11: 1 = Braking IGBT Active #10.12: 1 = Braking Resistor Alarm #10.13: 1 = Direction Commanded Negative, 0 = Direction Commanded Positive #10.14: 1 = Direction Running Negative, 0 = Direction Running Positive #10.15: 1 = Mains Loss SM-Applications Plus Module Error Codes Applications Module Error code is stored in parameter #15.50 on each drive.
  • Page 22 - 22 - V01.02.01 or earlier. 56 = Invalid timer unit configuration 57 = Function block does not exist. 58 = Flash PLC Storage corrupt. Occurs at startup and will mean that the PLC register set (P/Q/T/U) and menu 20 will not have been restored.
  • Page 23 - 23 - contain a position option module OR Attempt to change the Reference source or the Feedback source in more than one task. APC internal error. See Pr 81.38. This may be caused by one of the following: • CAM table too small •...
  • Page 24 - 24 - SM-Ethernet Module The Ethernet module error code is stored in parameter #17.50 on the Azimuth Drive 74= Overheated, 75= Not Responding 76 = Timeout, 80-83 = Inter-option communication failure. The SNTP connection warning code is stored in parameter #17.49 on the Azimuth Drive 3 = SNTP Delay 0 = None The network status is stored in parameter #17.06...

  • Page 25: Component Replacement

     Connect to the controller with a web browser by typing the IP into the address bar  Login using the username and password. Initially these are set to root/intertronic  Navigate to Protocols -> Scheduled Events -> Modify Configuration ...

  • Page 26: Sm-Applications Plus

    - 26 - SM-Applications Plus The SM-Applications Plus modules (Dark Green) are not interchangeable as they contain specific software for each drive. If a module fails a new one can easily be fitted, but the software must be uploaded into the new module. Wait at least two minutes after the controller has been powered down before removing the modules.

  • Page 27: Installing Winflash

    - 27 - Installing WinFlash WinFlash is a utility for downloading compiled programs and application solution components to the flash memory of the option modules. To upload new code into the modules, the drives must be powered up, with the REMOTE/OFF/STANDBY/OPERATE switch in the Standby position. To run, simply unzip Winflash370.zip and run winflash.exe.
  • Page 28 - 28 - Select “Download a compiled program” and click Next Click Browse and navigate to the folder where the .bin files are stored. Select the appropriate file depending which drive is to be updated. Click Next. Select CT-TCP/IP(Ethernet), enter the IP address of the controller and select Slot 1 from the dropdown list.
  • Page 29 - 29 - If updating the Azimuth Drive (Node 2), leave the Sub-node box empty. If updating the Elevation Drive (Node 1), enter 1 in the Sub-node box. Click Next Click Next Click the Red Button to start the upload. A progress bar will appear and the module will be updated. 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...

  • Page 30: Motor And Encoder Replacement

    - 30 - Motor and Encoder Replacement Motor Auto-Tune Procedure If a motor is being replaced, the new motor must be auto-tuned in order to properly set various drive parameters. This must be done BEFORE connecting the motor to any load or gearbox. ...

  • Page 31: Azimuth Motor

    - 31 - Azimuth Motor  Turn switch to OFF position  Power down the control system  Unplug the motor cables  Remove the 6 exposed screws holding the motor mounting plate onto the head of the pedestal.  Remove the motor, mount plate and harmonic drive wave generator by lifting vertically.
  • Page 32 - 32 -  Remove screw from end of motor shaft. (Screw will have threadlocker on threads and will be difficult to remove) 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...
  • Page 33 - 33 -  Slide harmonic drive wave generator, shaft adaptor, spacer and key off of the motor shaft. CAUTION: Take care not to damage the mating surfaces of these parts. 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...
  • Page 34 - 34 -  Remove the 4 screws holding the motor to the mounting plate and remove the motor  Assembly is the reverse of disassembly  Replace O-Rings and apply new medium strength threadlocker to motor shaft screw  If a new motor is to be used, the motor auto-tune procedure MUST be performed before connecting it to the gearbox...

  • Page 35: Azimuth Encoder

    - 35 - Azimuth Encoder **WARNING** Removing or replacing the encoders will result in loss of calibration for pointing and tracking functions. This should only be done once all other avenues have been explored. Once replaced, the antenna commissioning procedure must be completed again. ...
  • Page 36 - 36 -  Loosen the 3 clamps screws on the encoder. Note the relative position of the small dimple on the encoder. This can be used to roughly re-position the new encoder.  Remove the 4 screws holding the encoder to the base and slide encoder upwards off the center shaft ...

  • Page 37: Elevation Motor

    - 37 - Elevation Motor  Turn switch to OFF position  Power down control system  Unplug motor cables  Support motor and remove 4 attachment screws 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...
  • Page 38 - 38 -  Rotate motor so that set screw is visible through access hole in gearhead attached to end of jack. Loosen the clamp screw and slide motor out.  Assembly is the opposite of disassembly. Orient motor connectors downwards.

  • Page 39: Elevation Encoder

    - 39 - Elevation Encoder **WARNING** Removing or replacing the encoders will result in loss of calibration for pointing and tracking functions. This should only be done once all other avenues have been explored. Once replaced, the antenna commissioning procedure must be completed again. In order to remove elevation axis encoder, the reflector dish must be removed, as well as the supporting frame.
  • Page 40 - 40 -  Turn switch to OFF position and power down the system  While holding the reflector, remove 6 bolts holding reflector hub to supporting frame  Remove reflector and rest it on hub mounting service while removed from the pedestal. CAUTION: Only handle reflector assembly from the ribs.
  • Page 41 - 41 -  Remove shoulder bolt from jack clevis. CAUTION: Supporting frame will now be free to rotate.  Remove row of 4 screws attaching arm onto frame on both sides while supporting frame. 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...
  • Page 42 - 42 -  Remove frame  Loosen clamp screw from shaft collar  Remove 3 screws holding bushing. Repeat on opposite side  Repeat on opposite side.  Remove shaft collars and support arms 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...
  • Page 43 - 43 -  Remove upper access cover plate  Locate the wiring connector for the encoder and unplug the two halves  Loosen the 3 clamps screws on the encoder. Note the relative position of the small dimple on the encoder.
  • Page 44 - 44 -  Loosen set screws holding limit switch trip block onto shaft. There are two screws on opposite sides of the block. (Setscrews will have threadlocker on threads and will be difficult to loosen)  Firmly grasp the elevation shaft and slide out one side enough to free the encoder. CAUTION: Do NOT impact the shaft with a hammer or other object.
  • Page 45 - 45 -  Carefully feed the unplugged connector through the sliding cable guide and out  Installation is the reverse of disassembly. Make sure to re-attach the new encoder cable to the wiring bundle and include in cable wrapping Reapply new medium strength threadlocker where required.
  • Page 46 - 46 -  Before tightening shaft collars, make sure there is no axial play between the hub support frame and the turning head.  Power up control system  Before tightening the 3 clamp screws, mechanically adjust encoder to get as close to original reading as possible.

  • Page 47: Limit Switch Replacement

    - 47 - Limit Switch Replacement  Remove upper pedestal access cover  Turn switch to OFF position and power down system  Remove 4x mounting screws 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666 Fax 450 424 6611...
  • Page 48 Power up system and verify correct functioning of new limit switch. It may be necessary to adjust the limit switches so the hard limit is outside of the soft limit. ©InterTronic Solutions Inc. 2013 169 Joseph-Carrier, Vaudreuil-Dorion, Quebec, J7V 5V5, Canada Tel 450 424 5666...

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