COBHAM SAILOR 6000B Installation Manual
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COBHAM SAILOR 6000B Installation Manual

Mf/hf dsc 150w/150w fcc/250w/500w
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  • Page 1 SAILOR 6000B MF/HF DSC 150W/150W FCC/250W/500W Installation manual...
  • Page 3 Table of Contents SAILOR 6000B MF/HF DSC 150W/150W FCC/250W/500W Installation manual Document number: 98-144591-D Release date: December, 2016...
  • 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, Service and support, 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 specifi c 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.
  • 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 horn of the Antenna Tuning Unit or feeder wire when...

  • Page 7: Record Of Revisions

    Training information The SAILOR 6000B MF/HF DSC is designed for occupational use only and is also classifi ed as such. It must be ope- rated by licensed personnel only. It must only be used in the course of employment by individuals aware of both the hazards as well as the way to minimize those hazards.

  • Page 8: Related Documents

    Related documents Title and description Document number Installation guide SAILOR 630x MF/HF Control Unit 98-132396 Installation guide SAILOR 6000B MF/HF Transceiver Unit & Antenna Tuning Unit 98-144542 150 W/250 W/500 W User Manual SAILOR 6301 MF/HF Control Unit 98-131070 User Manual SAILOR MF/HF System 6000A/6000B MF/HF Radiotelex...

  • 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 ......................2-9 2.4 Antennas .............................2-12 2.5 DC Power cabling ........................2-17 2.6 Interconnection of units .....................2-18 2.7 Position and time information ..................2-25 2.8 Telex operation ........................2-26...
  • Page 10 Table of Contents Chapter 4 Service 4.1 Preventive maintenance .....................4-1 4.2 Calibrating the master oscillator ..................4-2 4.3 Cleaning the Air fi lter (500 W Transceiver only) ............4-5 4.4 System test and verifi cation ....................4-5 4.5 Software update ........................4-5 Chapter 5 Spare part exchange 5.1 Disassembling the Transceiver Unit (150 W/250 W) ..........5-1 5.2 Disassembling the Transceiver Unit (500 W) ............5-2 5.3 Transceiver Unit module location ...................5-3...

  • 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 (NBDP) is designed for mari- time applications in voluntary as well as compulsorily fi tted vessels. It offers simplex and semi-duplex SSB radiotelephone communication in the maritime mobile frequency bands between 1.6 and 30 MHz.

  • Page 12: Antenna Tuner

    Technical data User-programmable channels: 199 frequency pairs with mode (1-199) User-programmable stations: 40 stations with name, MMSI and station channel Supply voltage: Nominal 24V DC (-10 +30% — 21.6 - 31.2 V DC) With optional external AC power supply: 115/230V AC 50/60 Hz. Automatic change-over to DC in the absence of AC supply Power consumption: Rx Mode: Approximately 150 W...

  • Page 13: Receiver Characteristics

    Technical data 1.2.2 Receiver characteristics General:   Complies with ETSI 300373 in the ITU marine bands. Frequency range:  150 KHz to 30 MHz Frequency resolution:  100 Hz by keyboard entry 10 Hz, 100 Hz or 1 KHz search/fi ne-tune facility is provided  ...
  • Page 14 Technical data Frequency resolution:  100 Hz Output impedance: TX: 50 ohm The Antenna is matched by the Antenna Tuning Unit Power reduction:  Low power: 20 W PEP Intermodulation:  below -31 dB/PEP Spurious Emission: below -43 dB/PEP below -60 dB/PEP (FCC) Hum and noise: ...

  • Page 15: Dimensions And Weight

    Technical data 1.2.6 DSC/Telex modem characteristics DSC: DSC Equipment class: Class A Protocols:   ITU-R M. 493-13 Ship’s identity:   9-digit identity number NMEA interface: According to IEC 61162-1 GLL, RMC, ZDA, GGA, GNS TELEX: Protocols:   ARQ, FEC and Selective FEC Ship’s identity:  ...
  • Page 16 Technical data Chapter 1: General information 98-144591-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 ground connections must be installed with the greatest care using corrosion resistant materials. Cable routing shall be made so that the cables are protected from physical damage. Sharp cable bends especially on coaxial cables must be avoided and a suffi...
  • Page 18 Mounting the Units Control Units with fl ush 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 fl ush 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 suffi cient airspace below, above and in front of the unit for adequate air circulation through the cooling fi...
  • Page 20 Mounting the Units Transceiver Unit 500 W 3 9 1 m m 3 6 0 m m 2 1 7 m m 3 3 2 m m 1 6 0 m m 4 x ø8mm M i n . 1 0 0 0 Space for airflow and service Min.
  • Page 21 Mounting the Units 2.2.3 Mounting the Antenna Tuning Unit (ATU) The ATU may be positioned 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 suffi cient length of feed 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 Recommended ATU installation On a metal-hull vessel Install the ATU using the ATU Mounting Kit. The kit is stainless steel which can be bolted or welded to ship's hull to ensure good and solid connection as the radio system primary ground point. The mounting kit will, at the same time ensure straight and fl...
  • Page 24 Mounting the Units 2.2.5 SAILOR 6208 Control Unit Connection Box The SAILOR 6208 is used to convert the small cable dimension from preconfi gured cable 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 fi...

  • Page 25: Ground Connections

    Grounding considerations Ground connections 2.3.1 Grounding considerations Proper system grounding is the most important installation detail for obtaining proper RF performance of the MF/HF system. Two areas of grounding must be considered: a) The grounding connection between the ATU and grounding plane. b) The grounding connection of the TU and the externally connected equipment.
  • Page 26 Grounding connections 2.3.3 Minimizing ground loops By routing the coax cable very close together with the ATU grounding strap (i.e. secure good RF cou- pling between the two) all the way down to the ground-plane, there will be no RF ground loop left to generate any interference.
  • Page 27 Grounding connections R3.3 Copper strap 100 x 0.5mm L < 0.5m Dimensions are in mm. Copper strap cut-out at the ATU end In case the described copper strap material should not be readily available, a corresponding length of a 3-conductor cable of minimum 25mm² (AWG 3) stranded conductor cross sectional area may be used as illustrated below.
  • Page 28 Grounding connections In situations where the grounding connection of the ATU/antenna system cannot be kept within the indicated length limit, fi nding workable alternative means of grounding through e.g. a longer grounding connection between the ground-plane and the ATU, may require trial and error methods to be applied in order to fi...

  • Page 29: Antennas

    4000- and SAILOR 2000-series) in which SSB reception takes place using a common TX/RX antenna. The fact that SSB reception in the SAILOR 6000B-series takes place using a separate RX antenna implies that the same considerations that were given to selecting the proper position of the combined RX/TX antenna in previous systems, must be given to the position of both the RX and TX antenna in a SAILOR 6000B MF/HF system installation.
  • Page 30 Antennas 2.4.2 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 specifi cally for purpose of this discussion is of utmost importance for the proper performance of the equipment, i.e.
  • Page 31 Antennas The required compensation is achieved through insertion of the correct combination of inductors and capacitors in series with the antenna to form a resonance circuit at the given frequency. Hence, depending on the impedance of the antenna (i.e. the transmission frequency) a suitable combination of inductors and capacitors are put in-circuit through a number of relays, all controlled by the ATU processor during the tuning process.
  • Page 32 Antennas 2.4.3 Receiver antenna A passive type antenna is recommended as receiver antenna. The antenna should be erected well in the clear and kept away as far as possible from electrical equipment to minimize noise interference. Electrical installations such as cable braiding and instruments in the vicinity of the antenna should be grounded effectively and the instruments in question should be fi...
  • Page 33 12 dB Intermodulation: Reference signal 30 dBμV/m Intermodulation level above 80 dBμV/m Mechanical requirements Length of the antenna element: 1.0 to 1.5m Cobham have tested and recommends the AC Antennas KUM121 as a suitable choice. 98-144591-D Chapter 2: Installation 2-17...

  • Page 34: Dc Power Cabling

    DC Power cabling DC Power cabling The supply leads are connected to the supply terminal of the Transceiver Unit. The supply terminal is designed for 3 wire shielded power supply cable to meet international installation and EMC requirements. The safety ground wire is connected to the terminal showing ground symbol and shielding connected to the cable fi...

  • Page 35: Interconnection Of Units

    Interconnection of units Interconnection of units Transceiver Unit connector panel CU BUS CU LAN SYS COM 24V DC Control Unit connector panel TU-CU BUS 150 W/250 W Antenna Tuning Unit connector pane 500 W Antenna Tuning Unit connector panel TX/RX 98-144591-D Chapter 2: Installation 2-19...
  • Page 36 Interconnection of units 2-20 Chapter 2: Installation 98-144591-D...
  • Page 37 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 38 Interconnection of units Cable 3a: 2nd Control Unit - Transceiver Unit If a 2nd control unit is installed, this can be done by splitting and extending the CAN bus, using e.g. the 406208A control unit box. Note that the CAN bus must be terminated with 120 Ohm in each end of the bus (not in the middle!). The transceiver unit is terminated per default.
  • Page 39 Interconnection of units Cable 9: Transceiver Unit - SYS COM 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 'SYS CON' 10 way LTW NMEA_IN+ NMEA position input Brown NMEA_IN- NMEA position input...
  • Page 40 Interconnection of units Cable 11: Message Terminal Cable: Shielded high quality USB-cable Maximum cable length 1 m Cable 12: Ethernet Cable: STP/FTP CAT-5E or better 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...

  • Page 41: Position And Time Information

    Position and time information Position and time information 2.7.1 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 or SYSCON connector.

  • Page 42: Telex Operation

    Telex operation Telex operation The GMDSS Radiotelex Terminal is designed in accordance with relevant IMO, ITU and ETSI recom- mendation/specifi cations 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-R M.625.

  • Page 43: Id Programming

    ID programming ID programming 2.9.1 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 44: Setup Menu

    ID programming 2.9.2 Setup 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 Setup menu. Setup Menu Soft keys (2) Radio setup Scan Hang Time Scan Resume Scan Mode External PTT...

  • Page 45: Key Operation

    ID programming Setup Menu 7 x > Diagnostics Self Test ATU Status 8 x > System Confi g 6 Ch WR: Disabled Telex: Disabled 2.9.3 Change / reset MMSI MMSI no is requested at ‘fi rst 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 Setup Menu: Operation Operation...

  • Page 46: Programming Telex Id

    Programming Telex ID 2.10 Programming Telex ID Programming Telex ID is done via the in SAILOR 6018/6006 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 6018/6006 Message Terminal when TLX mode is selected.
  • Page 47 Programming Telex ID Figure Shift (FS), Letter Shift (LS), Carriage Return (CR) and Line Feed (LF) are normally not required inserted in the answerback. 98-144591-D Chapter 2: Installation 2-31...

  • Page 48: Confi Guration

    Other confi gurations considered installation features are accessed via the Service Interface. Please refer to the '97-147768 – User manual SAILOR 6000B MF/HF Service Interface', available for download at Cobham extranet.
  • Page 49 Confi guration 2.11.4 DSC Printer confi guration Operation Operation Function Press 2 x More Setup 5 x > System Setup Scroll down to Rotate Printer confi guration Select Press 2.11.5 DSC self test Menu Operation Function 3 x > DSC setup Scroll DSC Self Test Press...
  • Page 50 Option codes already generated either through purchase or as factory supplied for the 500 W systems may be looked up in the ‘Confi guration Key Search’ at www.cobham.com/satcom. Options already enabled in a system will remain activated even after ‘Factory default’ and ‘Factory Reset’...

  • Page 51: Final Installation Check

    Final installation check 2.11.11 TX band confi guration Operation Operation Function Press 2 x More Setup 1 x > Channel Setup Scroll down Rotate TX-Band Select Press Press New band Key In Band limits 1605,0 The freqs wanted 26175,0 Press Save Free run TX 2.11.12...
  • Page 52 Final installation check 2-36 Chapter 2: Installation 98-144591-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: Pa And Filters Module 60-122881

    Technical description LEDs on the ECM boards can be used to verify the following items: Normal state Status FPGA A Transmit protection detected in current PTT ses- sion (reset when PTT is released and pressed again) FPGA D Reset from CPU has not been detected after FPGA boot. FPGA B Blink Reserved...

  • 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 fi ve low-pass fi lters with relays and relay drivers. The PA and Filters receive the modulated RF input signal from the RX/EX Signal Path and delivers the amplifi...

  • Page 56: Antenna Tuning Unit

    Technical description SMPS module 60-126136 (500 W) This switched mode power supply contains a common input fi lter for 60-126136 and 60-126172 and supplies the PA. The input and output are galvanically isolated, and the output is fl oating with regards to ground.

  • Page 57: Power Control And Protection System

    Technical description 3.10.2 ATU module 60-131020 (500W) The ATU module comprises of a 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 towards the TU.
  • Page 58 Technical description 3.11.1 Power Amplifi er Protection The protection of the power amplifi er consists of V+I protection, SWR protection, and thermal protec- tion. When the output signal of the voltage detector at the output of the power amplifi er exceeds 10 V the output power is reduced to a safe level.

  • Page 59: Chapter 4 Service

    Chapter 4 Calibrating the master oscillator Service 4.1 Preventive maintenance Due to the modern design of the transceiver preventive maintenance can be reduced to a minimum provided the equipment is correctly installed. To ensure maximum performance and minimum repair trouble we recommend following the below stated items for preventive maintenance: The condition of the GMDSS Reserve source battery/batteries should be checked at frequent intervals.

  • Page 60: Calibrating The Master Oscillator

    Shield 4. Connect service PC to TU using Ethernet connection and Firefox browser to activate the TU WEB Service Interface. Refer to User manual SAILOR 6000B MF/HF Service Interface (Doc. 97-147768 ), available for download at Cobham SYNC. 5. Select Calibration tab and press 'Start' to initiate calibration process.
  • Page 61 Calibrating the master oscillator 7. The service Interface will perform 3 consecutive calibrations each in 20 steps. The calibration progress will be indicated on the screen. 98-144591-D Chapter 4: Service...
  • Page 62 Calibrating the master oscillator 11. The calibration process should result in a fi nal ppm value to lie within +/-0.030 and the Service Interface indicate "Calibration OK". However, if the fi nal ppm-value lies outside the +/- 0.030 limit the calibration attempt is ignored automatically and the original calibration value restored.

  • Page 63: Cleaning The Air Fi Lter (500 W Transceiver Only)

    Ref to ‘User Manual’ – chapter 'Service & Preventive Maintenance' 4.5 Software update For software upload refer to User manual SAILOR 6000B MF/HF Service Interface (Doc. 97-147768 ), avai- lable for download at the Cobham SYNC partner portal. Latest software for CU and TU is available for download also from the Cobham SYNC partner portal.
  • Page 64 Calibrating the master oscillator Chapter 4: Service 98-144591-D...

  • Page 65: 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 66: 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 67: 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 98-144591-D Chapter 5: Spare part exchange...
  • Page 68 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 identifi cation of parts and part numbers refer to the eShop at the Thrane &...

  • Page 69: Module Overview

    Transceiver Unit module location 5.4 Module overview Exciter Control module 60-139984 .SK1 C1399 C1335 U1307 L1301 R1700 L1305 L1304 R1720 C1749 C1338 C1306 C1336 U1308 R1702 L1704 C1337 C1339 C1745 C1768 R1729 R766 C709 C1743 C1774 C1746 R1739 C717 C1776 C1305 U1702 R1715...
  • Page 70 Module overview PA and fi lters module 60-123937 (FCC) PA and fi lters module 60-125886 (500 W) SMPS module 60-122882 (150 W/250 W) Chapter 5: Spare part exchange 98-144591-D...
  • Page 71 Module overview SMPS module 60-126172 (500 W) SMPS module 60-126136 (500 W) 98-144591-D Chapter 5: Spare part exchange...

  • Page 72: 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 73: Glossary

    Glossary Chapter 1: General information Automatic Gain Control Automatic Level Control Amplitude Modulation Antenna Tuning Unit Control Unit Digital Selective Call Forward Error Correction High Frequency 3-30 MHz DSC/Telex (modulation) SSB Telephony (modulation) Lower Side Band Medium Frequency 300-3000 KHz MMSI Maritime Mobile Service Identity Maritime Safety Information...
  • Page 74 Grossary Power Amplifi er Push To Talk Receive(r) Sitor SImplex Teletype Over Radio (Radio Telex) SMPS Switch Mode Power Supply Single Side Band (either lower or upper) Transmitter Unit Transmit Upper Side Band Glossary-2 98-144591-D...
  • Page 76 98-144591-D www.cobham.com/satcom...

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