COBHAM SAILOR 6300 MF/HF DSC Installation Manual

COBHAM SAILOR 6300 MF/HF DSC Installation Manual

150w/150w fcc/250w/500w

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SAILOR 6300 MF/HF DSC
150W/150W FCC/250W/500W
Installation manual

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Summary of Contents for COBHAM SAILOR 6300 MF/HF DSC

  • Page 1 SAILOR 6300 MF/HF DSC 150W/150W FCC/250W/500W Installation manual...
  • Page 3 Table of Contents SAILOR 6300 MF/HF DSC 150W/150W FCC/250W/500W Installation manual Document number: 98-130890-D Release date: November, 2013...
  • Page 4 & Thrane A/S are periodically revised and updated. Anyone relying on this information should acquire the most current version e.g. from www.cobham.com/satcom or from the distributor. Thrane & Thrane A/S is not responsible for the content or accuracy of any translations or reproductions, in whole or in part, of this manual from any other source.
  • Page 5 Safety summary The following general safety precautions must be observed during all phases of operation, service and repair of this equipment. Failure to comply with these precautions or with specific warnings elsewhere in this manual violates safety standards of design, manufacture and intended use of the equipment. Thrane & Thrane assumes no liability for the customer's failure to comply with these requirements. GROUND THE EQUIPMENT To minimise shock hazard, the equipment chassis and cabinet must be connected to an electrical ground and the cable instructions must be followed.
  • Page 6 RF exposure hazards and instructions Your Thrane & Thrane radio generates electromagnetic RF (radio frequency) energy when transmitting. To ensure that you and those around you are not exposed to excessive amounts of energy and thus to avoid health hazards from excessive exposure to RF energy, all persons must obey the following: Caution! Never touch the Antenna Tuning Unit or feeder wire when the MF/HF...
  • Page 7 Terminal Equipment and is intended for use in maritime environment. SAILOR 6300 MF/HF DSC is designed for occupational use only and must be operated by licensed personnel only. SAILOR 6300 MF/HF DSC is not intended for use in an uncontrolled environment by general public.
  • Page 8: Related Documents

    Installation A whip antenna with a maximum power gain of 3 dBi must be mounted at least 12.6 ft. (3.9m) above the highest deck where people may be staying during radio transmissions. The distance is to be measured vertically from the lowest point of the antenna.
  • Page 9: Table Of Contents

    Table of Contents Table of Contents Chapter 1 General information 1.1 Introduction ..........................1-1 1.2 Technical data ...........................1-1 Chapter 2 Installation 2.1 Description ..........................2-1 2.2 Mounting the units .........................2-1 2.3 Ground connections ......................2-8 2.4 Grounding considerations ....................2-9 2.5 Antennas .............................2-11 2.6 DC Power cabling ........................2-17 2.7 Interconnection of units .....................2-18 2.8 Position and time information ..................2-24 2.9 Telex operation ........................2-25...
  • Page 10 Table of Contents 3.11 Transceiver unit block diagram ..................3-5 3.12 Transceiver unit interconnection diagram ..............3-7 3.13 Antenna Tuning Unit ......................3-9 3.14 Power control and protection system ................3-11 Chapter 4 Service 4.1 Preventive maintenance .....................4-1 4.2 Cleaning the Air filter (500 W Transceiver only) ............4-1 4.3 System test and verification ....................4-2 4.3 Software update ........................4-2 Chapter 5 Spare part exchange 5.1 Disassembling the Transceiver Unit (150 W/250 W) ..........5-1...
  • Page 11: Chapter 1 General Information

    Chapter 1 Technical data Chapter 1: General information General information 1.1 Introduction The 150 W/250 W/500 W MF/HF transceiver with integrated DSC and telex is designed for maritime applications in voluntary as well as compulsorily fitted vessels. It offers simplex and semi-duplex SSB radiotelephone communication in the maritime mobile frequency bands between 1.6 and 30 MHz.
  • Page 12 Technical data User-programmable channels: 199 frequency pairs with mode (1-199) User-programmable stations: 40 stations with name, MMSI and station channel Output power: Refer to sections concerning Receiver / Transmitter characteristics Supply voltage: Nominal 24V DC floating (-10 +30%) With optional external AC power supply: 115/230V AC 50/60 Hz.
  • Page 13 Technical data Input impedance:  Rx/Tx : 50 ohm The Antenna is matched by the antenna amplifier in the Antenna Tuning Unit DSC/Telex: 50 ohm 12V DC / 20 mA is available for possible use of active antenna. Sensitivity:  Telephony (J3E): below 11 dBµV for 20 dB Sinad Broadcast (A3E): below 25 dBµV for 20 dB Sinad...
  • Page 14 Technical data Output power 500W SSB: 1.6-4 MHz 400 W PEP +0/-1.4 dB 4-27 MHz 500 W PEP ±1.4 dB into 50 ohm Antenna, voice for a duty cycle less than 55% and modulation rate greater than 3 baud.   Reduction to 200 W when continuously keyed with duty cycle greater than 55% during 1 min.
  • Page 15 Technical data 1.2.6 DSC/Telex modem characteristics DSC: DSC Equipment class: Class A Protocols:   ITU-R M. 493-13, M. 541-9 Ship’s identity:   9-digit identity number Navigator interface: According to IEC 61162-1 GLL, RMC, ZDA, GGA, GNS TELEX: Protocols:   ITU-R M. 625-3 (incl. M. 476-5), M. 490, M.
  • Page 16 Technical data Chapter 1: General information 98-130890-D...
  • Page 17: Chapter 2 Installation

    Chapter 2 Mounting the Units Installation Description Correct installation of the equipment is important for maximum performance and reliability. Antennas and earth connections must be installed with the greatest care using corrosion resistant materials. Cable routing shall be made so the cables are protected from physical damage. Sharp cable bends especially on coaxial cables must be avoided and a sufficient number of clips or straps should be used to secure the cables.
  • Page 18 Mounting the Units Control Units with flush mounting bracket Weight: Drilling plan Flush mount bracket 0.04 kg R2.5mm x 4 Flush mount template WARNING: Only use screws supplied with 227mm mounting kit for attaching flush Remove material from shaded area only! mounting bracket to Control Unit.
  • Page 19 Mounting the Units 2.2.2 Mounting the Transceiver Unit (TU) The Transceiver Unit should be installed in a dry place and consideration should be given to acces- sibility for servicing. It is important to provide sufficient airspace below, above and in front of the unit for adequate air circulation through the cooling fins.
  • Page 20 Mounting the Units Transceiver Unit 500 W Note: 1) Space for cable and airflow: min. 150 mm. 2) Space for service access: min. 200 mm. 3) Space for service access: min. 1000 mm. All dimensions are in mm. Cable fitting 99-126338 Cable fitting 38417...
  • Page 21 Mounting the Units 2.2.3 Mounting the Antenna Tuning Unit (ATU) The ATU may be mounted up to 100 metres from the Transceiver Unit using just one RG-213/U or better coaxial cable. The ATU must be installed outside in a convenient position to have good access for sufficient length of feeder wire to meet the antenna connection point.
  • Page 22 Mounting the Units Antenna Tuning Unit 500 W 4-0-32426 1) Distance to metal constructions: min. 150 2) Space for service access: min. 500 3) Space for cable and service access: min. 200 Dimensions are in mm Tolerance: +/- 1 mm Mounting hole: ø8 Weight: 17 Kg Chapter 2: Installation...
  • Page 23 Mounting the Units 2.2.4 SAILOR 6208 Control Unit Connection Box The SAILOR 6208 is used to convert the small cable dimension from LTW plug to spring loaded terminals with strain relief for connection to larger cable dimensions. The box is used to connect the Transceiver Unit to Control Units and Message Terminal respectively. The box is fitted with optional 120 ohm CAN-BUS termination.
  • Page 24: Ground Connections

    Ground connections Ground connections 2.3.1 Antenna Tuning Unit As the earth connection of a transmitter is a very important part of the antenna system, it is of the utmost importance to keep in mind that the earth connection of the Antenna Tuning Unit must have the lowest possible RF-impedance.
  • Page 25: Grounding Considerations

    Grounding considerations Grounding considerations Proper system grounding is one of the most important installation details. Two areas of grounding must be considered: a) The ground connection between the ATU and earth plane. b) The ground connection of the TU and the externally connected equipment. Each area requires separate considerations even though they are interrelated.
  • Page 26 Grounding considerations 2.4.2 RF ground loop It is not always possible or practical to mount the ATU using a very short strap to the actual ground- plane. In such a case the coaxialcable may be connected between units with different ground potentials causing RF loop-current to flow.
  • Page 27: Antennas

    Antennas Antennas 2.5.1 Transceiver Antenna The equipment is used with common transmitting and receiving antenna. The antenna should be erected in the open, away from conducting object such as derricks etc. which may cause reduction of the radiated power. Insulators should be of the best type having low leakage even when wet. Stays, wires, steel masts etc.
  • Page 28 Antennas 2.5.2 Recommended ATU installation On a metal-hull vessel Install the ATU on an ATU Mounting Kit. The kit is stainless steel which can be bolted or welded to ship's hull to ensure good and solid connection in the radio system primary ground point. The mounting kit will at the same time ensure straight and flat mounting for the ATU cabinet and provide good airflow around the ATU for better heat dissipation.
  • Page 29 Antennas 2.5.3 Considerations on antenna length requirements Antenna impedance The length of the transmitting antenna used with MF/HF equipment in general and the MF/HF equip- ment specifically for purpose of this discussion is of utmost importance for the proper performance of the equipment, i.e.
  • Page 30 Antennas Function of the Antenna Tuning Unit (ATU) The MF/HF transmitter power amplifier (PA) provides a fixed output impedance of 50 ohms over its operating frequency range to which the load (the antenna) should be matched (i.e. load should prefer- ably be 50 ohms also) in order for the transmitter to deliver its full power output to the load.
  • Page 31 Antennas Electrical specifications transmitting antennas Frequency range 1.6-30 MHz Power rating 1.5 kW PEP Impedance See separate section Polarization Vertical Pattern Omnidirectional Electrical length 5.5 m (18 ft) (add 0.5 m (1.7 ft) for base mount) 6.5 m (21 ft) (add 0.5 m (1.7 ft) for base mount) 7.5 m (25ft) (add 0.5 m (1.7 ft) for base mount subtract 0.7 m (2.1 ft) for bracket mount) The connection to the transmitting antenna is by a single ended wire...
  • Page 32 Antennas 2.5.4 DSC watch receiver antenna The DSC watch receiver antenna may be an active or a passive type. The antenna should be erected well in the clear and kept away as far as possible from electrical equip- ment in order to minimize noise. Electrical installation such as cable braiding and instruments in the vicinity of the antenna should be earthed effectively, and the instruments in question should be fitted with noise-interference suppression devices, effective in the range 0.1 to 30 MHz.
  • Page 33: Dc Power Cabling

    DC Power cabling DC Power cabling The supply leads are connected to the supply terminal strip of the Transceiver Unit. The supply termi- nal strip is adapted for 3 wire shielded power supply cable to meet international installation and EMC requirements.
  • Page 34: Interconnection Of Units

    Interconnection of units Interconnection of units Transceiver Unit connector panel TU-CU BUS SUPPLY ALARM DSC RX RX/TX 24V DC 99-130948 Control Unit connector panel TU-CU BUS 99-130950 150 W/250 W Antenna Tuning Unit connector pane 40631 500 W Antenna Tuning Unit connector panel TX/RX 99-126340 2-18...
  • Page 35 Interconnection of units 98-130890-D Chapter 2: Installation 2-19...
  • Page 36 Interconnection of units Cable 1: Control Unit - ACC Cable: 10 x LTW-UL2464 26AWG Cable-connector: 10 way (ex. LTW) 5 m cable with connector supplied Control Unit Designation Remarks Color 'ACC' 10 way NMEA+ NMEA position input Brown NMEA- NMEA position input Blue 2182 Select OC output.
  • Page 37 Interconnection of units Cable 3a: 2nd Control Unit - Transceiver Unit 2 Control Units installed must be connected in a serial CAN-bus installation. The cable is defined as a CAN-bus Drop-line, max 5 m. Cable 15 between 2 connection boxes 406208A is defined as CAN-bus backbone and may be up to 100 m using tvisted pair cable 6 x 2 x 0.5 mm²...
  • Page 38 Interconnection of units Cable 9: Transceiver Unit - AUX Cable: 10 x LTW-UL2464 26AWG Cable-connector: 10 way (ex. LTW) 6 m cable with connector, available from eShop Transceiver Unit Designation Remarks Color 'AUX' 10 way LTW NMEA+ NMEA position input Brown NMEA- NMEA position input...
  • Page 39 Interconnection of units Cable 12: Ethernet Cable: STP CAT-5E Maximum cable length 100 m Cable 13: Transceiver Unit – 24 V Battery For power cable information see section 2.6 DC Power Cabling Cable 14: Message terminal Cable: 5 x LTW-UL2464 24AWG 5 m cable supplied with Telex option kit Message terminal...
  • Page 40: Position And Time Information

    Position and time information Position and time information 2.8.1 Connection of Navigation Equipment Navigation equipment complying with the NMEA 0183/IEC 61162-1 standard may be connected for automatic position and time updating. Connection is made to the NMEA+/NMEA- connections in the Control Unit ACC connector or the NMEA+/NMEA- connections in the Transceiver Unit AUX connector.
  • Page 41: Telex Operation

    Telex operation Telex operation The GMDSS Radiotelex Terminal is designed in accordance with relevant IMO, ITU and ETSI recom- mendation/specifications and has been approved for shipboard installations to be operating within the Global Maritime Distress and Safety System. It supports world-wide ship-to-ship, shore-to-ship and ship-to-shore communication by utilizing the radiotelex protocols described in ITU- Rec.
  • Page 42: Id Programming

    ID programming 2.10 ID programming 2.10.1 Front Panel Loudspeaker. Four soft keys with function title in the display. Large TFT color display. Alphanumerical keys to enter Rx or Tx frequency or text strings. CH button for channel selection. Rx/Tx Key to enter Tx or RX frequency. Connector for handset or handmicrophone.
  • Page 43 ID programming 2.10.2 Set-up Menu Menu items shown in bold is only available in the menu structure when it is extended by access password >1-2-3-4-5< in the System Set-up menu. Set-up Menu Soft keys (2) Radio set-up Scan Hang Time Scan Resume Scan Mode External PTT...
  • Page 44 ID programming 2.10.3 Change / reset MMSI MMSI no is requested at ‘first time power up’ and directly programmed via the numeric keyboard (4) If a MMSI reset or change of registration is needed it is accessed via the Set-up Menu: Operation Operation Function...
  • Page 45: Programming Telex Id

    Programming Telex ID 2.11 Programming Telex ID Programming Telex ID is done via the in SAILOR 6006 Message Terminal. Requires that the Telex option has been enabled in the radio (see ‘Option Code Activation’) and TLX mode selected on the Control Unit (12). The MMSI (9 digits) is automatically transferred from radio to SAILOR 6006 Message Terminal when TLX mode is selected.
  • Page 46 Programming Telex ID Figure Shift (FS), Letter Shift (LS), Carriage Return (CR) and Line Feed (LF) are normally not required inserted in the answerback. 2-30 Chapter 2: Installation 98-130890-D...
  • Page 47: Configuration

    Other configurations considered installation features are accessed via the ‘Radio Service Tool’. Please refer to ‘SAILOR 6222/6248/6249 VHF and SAILOR 6300 MF/HF Service tool Manual’ – 98-133342, available for download at www.cobham.com/satcom. 2.12.1 CU configuration Priority setting is via the menu and Main CU is High Priority = ON and Slave CU is High Priority = OFF.
  • Page 48 Configuration 2.12.3 DSC printing ON/OFF Operation Operation Function Press 2 x More Set-up 3 x > DSC Set-up Scroll down to Rotate Print DSC: OFF Select Press Select Select ON/OFF Any LAN connected printer can now be selected to print DSC messages from the log. Please check ‘DSC Printer Configuration’.
  • Page 49 Option codes already generated either through purchase or as foc codes for the 500 W systems may be looked up in the ‘Configuration Key Search’ at www.cobham.com/satcom. Options already enabled in a system will remain activated even after ‘Factory default’ and ‘Factory Reset’...
  • Page 50 Watch Receiver 2.12.14 Special configuration Coast station configuration and special facilities are configured via the Radio Service Tool. Please refer to 'SAILOR 622286248/6249 VHF and MF/HF Service tool Manual' - 98-133342 available for download at www.cobham.com/satcom. 2-34 Chapter 2: Installation 98-130890-D...
  • Page 51: Final Installation Check

    Final installation check 2.13 Final installation check Refer to ‘User Manual’ – chapter Service & Preventive Maintenance. 98-130890-D Chapter 2: Installation 2-35...
  • Page 52 Final installation check 2-36 Chapter 2: Installation 98-130890-D...
  • Page 53: Chapter 3 Technical Description

    Chapter 3 Technical description Control Unit The Control Unit consists of a main module 60-127962 and two sub modules: HMI module 60-127963 and the Intercon module 60-127964. The main module consists of the digital part, i.e. the microprocessor, program FLASH, SDRAM, TU-CU Bus communication driver and Ethernet interface.
  • Page 54: Rx/Ex Signal Path Module 60-122880

    Technical description After frequency conversion to 455 kHz the signal is fed to 455 kHz IF2 AGC amplifier before led to final detection / conversion to 1700 Hz. The Signal is filtered out by 1700 Hz Audio filter and afterwards led to limiting amplifier thus creating the DSC output for further processing.
  • Page 55: Pa And Filters Module 60-123937 (Fcc)

    Technical description PA and Filters module 60-123937 (FCC) The PA and Filters module includes PA drivers, PA-stage, protection circuits, bias circuits, key circuit and five low-pass filters with relays and relay drivers. The PA and Filters receive the modulated RF input signal from the RX/EX Signal Path and delivers the amplified and filtered output signal to the TX/RX connector via a receive/transmit relay on the Control/Intercon module.
  • Page 56 Transceiver unit block diagram (150W/250W) 3.10 SMPS module 60-126136 (500 W) This switched mode power supply contains a common input filter for 60-126136 and 60-126172 and supplies the PA. The input and output are galvanically isolated, and the output is floating with regards to ground.
  • Page 57: Transceiver Unit Block Diagram

    Transceiver unit interconnection diagram 3.11 Transceiver unit block diagram 150 W/250 W 98-130890-D Chapter 3: Technical description...
  • Page 58 Transceiver unit interconnection diagram 500 W Chapter 3: Technical description 98-130890-D...
  • Page 59: Transceiver Unit Interconnection Diagram

    Transceiver unit interconnection diagram 3.12 Transceiver unit interconnection diagram 150 W/250 W SUPPLY OFF SUPPLY ON BATINFO +25V +25V +25V -15V -15V +15V +15V +7.5V +7.5V ADR0 ADR1 ADR2 ADR3 DATA0 DATA1 DATA2 DATA3 DATA4 DATA5 DATA6 DATA7 STROBE PA KEY PA TEMP PA PROTEC FILPEAK...
  • Page 60 Transceiver unit interconnection diagram 500 W SUPPLY OFF SUPPLY ON BAT INFO SMPS +24V +24V +24V 60-126172 -15V -15V +15V +15V +7.5V +7.5V GND 14 PA AND FILTERS 60-125886 +7.5 V +7.5 V +7.5 V +7.5 V +7.5 V +7.5 V +15 V +15 V +15 V...
  • Page 61: Antenna Tuning Unit

    Antenna Tuning Unit 3.13 Antenna Tuning Unit 3.13.1 ATU module 60-122883 (150 W/250 W) The ATU module comprises tuning network, measuring system and micro-controller circuits. The ATU module matches the impedance of the antenna to 50 ohm in order to gain the best possible SWR. The ATU module communicates tuning process and frequency information with the transceiver unit.
  • Page 62 Antenna Tuning Unit 3.13.2 ATU module 60-131020 (500W) The ATU module comprises tuning network, measuring system and micro-controller circuits. The ATU module matches the impedance of the antenna to 50 ohm in order to gain the best possible SWR. The ATU module communicates tuning process and frequency information with the transceiver unit.
  • Page 63: Power Control And Protection System

    Power control and protection system 3.14 Power control and protection system The Transceiver has an automatic power level system, which ensures that optimum power is delivered to the Antenna. The Tune Sequence, which is automatically initiated when keying the transmitter after a frequency change, makes the Tuning Network of the Antenna Tuning Unit tune to the best obtaina- ble SWR.
  • Page 64 Power control and protection system Block diagram 3-12 Chapter 3: Technical description 98-130890-D...
  • Page 65: Chapter 4 Service

    Chapter 4 Service 4.1 Preventive maintenance Due to the modern design of the transceiver preventive maintenance can be reduced to a minimum pro- vided the equipment is correctly installed. To ensure maximum performance and minimum repair trouble we recommend you to follow the below stated headlines for preventive maintenance. 1.
  • Page 66: System Test And Verification

    4.4 Software update For Software upload please refer to 'SAILOR 622286248/6249 VHF and MF/HF Service tool Manual' - 98-133342 available for download at www.cobham/satcom. Latest SW for CU and TU is available for download at www.cobham/satcom. Software version1.06 or higher in TGZ files is uploaded using the Radio Service Tool, software version 1.06 or higher in TIIF files is uploaded using the TMA tool version 1.04 or higher. Chapter 4: Service...
  • Page 67: Chapter 5 Spare Part Exchange

    Chapter 5 Spare part exchange 5.1 Disassembling the Transeciver Init (150 W/250 W) To open the transceiver unit loosen the 4 screws (2 on each side) on the side of the cabinet. Move the screws to the side to unlock the TU. Now open the TU by pulling the front door towards you. Loosen 4 screws Screw A2 M6x30mm 87.838...
  • Page 68: Disassembling The Transceiver Unit (150 W/250 W)

    Disassembling the Transceiver Unit (500 W) 5.2 Disassembling the Transceiver Unit (500 W) To remove the transceiver cover loosen the 4 screws (2 on each side) on the side of the cabinet and pull the cover from the transceiver. Loosen 4 screws M6x16 SMPS modules Loosen 17 screws...
  • Page 69: Transceiver Unit Module Location

    Transceiver Unit module location 5.3 Transceiver Unit module location 150 W/250 W Transceiver Unit The following modules are available as service parts. C144 C180 98-130890-D Chapter 5: Spare part exchange...
  • Page 70 Transceiver Unit module location 500 W Transciver Unit The modules and internal cables illustrated in the following pages are available as spare parts, some as individual parts and others as part of a subassembly or a set. For identification of parts and part numbers refer to the eShop at the Thrane &...
  • Page 71 Transceiver Unit module location 98-130890-D Chapter 5: Spare part exchange...
  • Page 72: Module Overview

    Module overview 5.4 Module overview Control / Intercon. module 60-127961 R429 R430 C239 R283 C312 R515 R266 R297 C383 C219 C220 C268 R184 C221 C387 R508 R288 R323 C409 R347 R392 R493 R132 R185 R294 R320 R124 C226 C101 R321 R467 C320 C290...
  • Page 73 Module overview PA and filters module 60-122881 (150 W/250 W) PA and filters module 60-123937 (FCC) 98-130890-D Chapter 5: Spare part exchange...
  • Page 74 Module overview PA and filters module 60-125886 (500 W) SMPS module 60-122882 (150 W/250 W) SMPS module 60-126172 (500 W) Chapter 5: Spare part exchange 98-130890-D...
  • Page 75 Module overview SMPS module 60-126136 (500 W) 98-130890-D Chapter 5: Spare part exchange...
  • Page 76: Required Service Tools

    Accessory list 5.5 Required service tools 150 W/250 W For disassembling transceiver unit: Slotted screwdriver For shield cover, print and cables: Torx screwdriver T10 500 W For disassembling transceiver unit: Hexagonal socket wrench 1/4" lenght min.16 cm For transceiver modules and cables: Torx screwdriver T10 Slottet screwdriver Spanner for M5 nut...
  • Page 77: Glossary

    Glossary Chapter 1: General information Automatic Gain Control Automatic Level Control Amplitude Modulation Antenna Tuning Unit Control Unit Continuous Wave (modulation, used for morse communication) Digital Selective Call Forward Error Correction (Broadcast) High Frequency DSC/Telex (modulation) SSB Telephony (modulation) Lower Side Band Medium Frequency MID Maritime Identification Digits...
  • Page 78 Grossary NMEA National Marine Electronics Association Power Amplifier Push To Talk RTTY Radioteletype (Radio Telex) Receive(r) Sitor SImplex Teletype Over Radio (Radio Telex) SMPS Switch Mode Power Supply Single Side Band Transmitter Unit Transmit(ter) Upper Side Band Glossary-2 98-130890-D...
  • Page 80 98-130890-D www.cobham.com/satcom...

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