COBHAM SAILOR 1000 XTR Ka 4.5W ADU Installation Manual
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COBHAM SAILOR 1000 XTR Ka 4.5W ADU Installation Manual

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Summary of Contents for COBHAM SAILOR 1000 XTR Ka 4.5W ADU

  • Page 1 SAILOR XTR Ka Installation manual...
  • Page 2 SAILOR XTR Ka Quick guide Installation wizard This quick guide is for experienced service personnel who have installed the SAILOR XTR Ka system before. It lists the minimum configuration tasks you have to make before the system can be used on-air on a satellite.
  • Page 3 SAILOR XTR Ka 4.5W/9W Installation manual for 100 cm and 60 cm antennas Document number: 98-175666-A Release date: 29 November 2021...
  • Page 4 In the event of any discrepancies, the English version shall be the governing text. Thrane & Thrane A/S is trading as Cobham SATCOM. Company address Thrane &...
  • 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.
  • Page 6 transmitters on page 2-16 – it may cause damage to the antenna. Compass Safe Distance: SAILOR 1000 XTR Ka 4.5W and 9.0W antenna (ADU): min. 140 cm (IEC 60945). SAILOR 7516A BDU (Below Deck Control Unit): min. 30 cm (IEC 60945). SAILOR 7023A GMU (GX Modem Unit): min.
  • Page 7 SAILOR 7516A Below Deck Unit (BDU): min. 30 cm (IEC 60945). Service User access to the interior of the BDU is prohibited. Only a technician authorized by Cobham SATCOM may perform service - failure to comply with this rule will void the warranty. Access to the interior of the Above Deck Unit is allowed.
  • Page 8 Personnel installing or servicing the system must be properly trained and authorized by Cobham SATCOM. It is important that you observe all safety requirements listed in the beginning of this manual, and install the system according to the guidelines in this manual.
  • Page 9 Some materials can be dangerous. CAUTION! Do not use materials that are not equivalent to materials specified by Cobham SATCOM. Materials that are not equivalent can cause damage to the equipment. CAUTION! The system contains items that are electrostatic discharge sensitive.
  • Page 10 Table of contents Chapter 1 Introduction SAILOR XTR Ka system ......................1-1 Part numbers and options ....................1-9 Chapter 2 Installation What’s in the box ........................2-1 Site considerations ........................2-2 Installation of the ADU (100 cm) ................2-20 Installation of the ADU (60 cm) ................... 2-24 Installation of the BDU .......................
  • Page 11 Table of contents Specifications (100 cm antenna) ..................A-2 Specifications (60 cm antenna) ..................A-4 Patents ..............................A-6 Outline drawings ..........................A-7 Appendix B Dual antenna solution Introduction ............................ B-1 Installation of the dual antenna solution ..............B-1 Configuration of the dual antenna solution ............B-4 Flow chart for installation of the dual antenna solution ......
  • Page 12 Chapter 1 Introduction This chapter has the following sections: • SAILOR XTR Ka system • Part numbers and options 1.1 SAILOR XTR Ka system The SAILOR XTR Ka is a unique stabilized maritime GX antenna system operating in the Ka- band (17.7 to 30 GHz).
  • Page 13 GMU with 8+2 LAN, RS-232 and RS-422 and I/O connector.   No scheduled maintenance.  Few spare parts, easy to service  Support for Cobham ConnectIT  Prepared for third-party IP devices in ADU The system is set up using the built-in Installation wizard. 98-175666-A Chapter 1: Introduction...
  • Page 14 SAILOR XTR Ka system Service friendly system The system configuration is saved in several modules, there is no loss of data at repair. There is a switch in the ADU to turn off the power to the antenna. All modules have an LED status indicator.
  • Page 15 SAILOR XTR Ka system Modules in the ADU (100 cm) Figure 1-3: SAILOR XTR Ka (100 cm): ADU modules 1/2 1. GNSS module (GPS, GLONASS, BEIDOU). 2. XTR Antenna Control Module (ACM). 3. ADU power on/off. 4. Cross elevation motor. 5.
  • Page 16 SAILOR XTR Ka system Figure 1-4: SAILOR XTR Ka (100 cm): ADU modules 2/2 8. Azimuth motor. 9. Azimuth zero reference module. 10. Rotary joint. 11. Feed horn. 98-175666-A Chapter 1: Introduction...
  • Page 17 SAILOR XTR Ka system Modules in the ADU (60 cm) Figure 1-5: SAILOR XTR Ka (60 cm): ADU modules 1/2 1. GNSS module (GPS, GLONASS, BEIDOU). 2. XTR Antenna Control Module (ACM). 3. ADU power on/off. 4. Cross elevation motor. 5.
  • Page 18 SAILOR XTR Ka system Figure 1-6: SAILOR XTR Ka (60 cm): ADU modules 2/2 8. Azimuth motor. 9. Azimuth zero reference module. 10. Rotary joint. 11. Feed horn. 12. Azimuth motor driver. 1.1.2 Below Deck Unit (BDU) The BDU contains all user interfaces and manages all communication between the ADU and the connected VSAT modem, a connected PC and an optional FleetBroadband service communication line.
  • Page 19 SAILOR XTR Ka system BDU connector ID Type Function NMEA0183 RJ-45 Vessel gyro input GPIO RJ-45 General Purpose I/O LAN 1 RJ-45 VSAT modem LAN 2 RJ-45 User LAN LAN 3 RJ-45 User LAN LAN 4 RJ-45 User LAN RS 232 RJ-45 VSAT modem serial interface RS422 RJ-45...
  • Page 20 The following model and part numbers are available for the SAILOR XTR Ka system: Part number Model number Description 407509C-00540 7509C SAILOR 1000 XTR Ka 4.5W ADU 407509D-00540 7509D SAILOR 1000 XTR Ka 9.0 ADU 407506A-00540 7506A SAILOR 600 XTR Ka 4.5W ADU...
  • Page 21 Chapter 2 Installation This chapter has the following sections: • What’s in the box • Site considerations • Installation of the ADU (100 cm) • Installation of the ADU (60 cm) • Installation of the BDU • Installation of the modem •...
  • Page 22 Site considerations WARNING! To avoid electric shock, do not apply power to the system if there is any sign of shipping damage to any part of the front or rear panel or the outer cover. Read the safety summary at the front of this manual before installing or operating the system.
  • Page 23 Cobham SATCOM recommends NOT to modify the radome or change it to another type. Exchanging or modifying the radome will not void the general warranty for material and workmanship etc.
  • Page 24 Site considerations Ship motion and offset from the ship’s motion centre When installing the ADU you must consider the mounting height carefully. The higher up the ADU is mounted, the higher is the linear g force applied to the ADU. The g force also depends on the roll period of the ship, see Table 2-2.
  • Page 25 Site considerations 3. Elevate the ADU by mounting it on a mast or on a mounting pedestal on a deck or deck house top to avoid obstruction. Figure 2-2: Signal degradation because of obstructing objects, look angle -18° to 118° Blocking zones –...
  • Page 26 Site considerations Figure 2-4: Blocking zone with no-transmit zones, elevation angle (example) 2.2.3 ADU mast flange and mast length The system is designed for harsh environmental conditions at sea, both in regards to vibration amplitude and speed. The antenna system performs optimally when mounted on a properly designed foundation.
  • Page 27 Site considerations ADU mast flange (100 cm) For best performance, do as follows: 1. Provide a mast flange with a minimum of four gusset plates. 2. Fit the top of the ADU mast with a flange with clearance holes matching the bushings in the radome and with minimum 4 gusset plates.
  • Page 28 Site considerations ADU mast flange (60 cm) For best performance, do as follows: 1. Provide a mast flange with a minimum of four gusset plates. 2. Fit the top of the ADU mast with a flange with clearance holes matching the bushings in the radome and with minimum 4 gusset plates.
  • Page 29 Site considerations 5. Use the dimensions in the following figure to prepare the mast flange for mounting of the ADU. The following figure shows the bottom view of an antenna. 226.4 THREAD for GROUNDING M10 (depth: 22mm) Figure 2-11: ADU, bottom view (60 cm) Mast length and diameter The mast wall thickness is in the following design examples set to 5 mm and the brace wall thickness to 4 mm.
  • Page 30 Site considerations The tables list the values for steel masts. For aluminium masts, the Note free mast length is reduced to 75% of the values for steel. Bracing and rigid masts can still not prevent vertical vibration if the mast Note is attached to a deck plate that is not rigid.
  • Page 31 Site considerations Outer Thickness Max. free mast Outer Wall Mast with 2 Diameter length (steel), Diameter Thickness braces for brace brace (mm) (mm) (mm) (mm) Table 2-5: Mast dimensions with 2 braces The tables in the next sections give suggested design values for the free mast length. The tables list the values for steel masts.
  • Page 32 Site considerations Outer Max. free Outer Wall Thickness Diameter Mast with 3 braces mast length Diameter Thickness for brace for brace (steel), (m) (mm) (mm) (mm) (mm) 30-40° Table 2-7: Mast dimensions with 3 braces Max. free Outer Thickness Outer Wall mast Diameter...
  • Page 33 Site considerations Mast length 60 cm Mast without braces The following figure shows the maximum mast length over the outer mast diameter. Figure 2-13: Maximum mast length for a mast without braces (60 cm) Example: The mast outer diameter is 150 mm. Then the mast length must be shorter than 82 cm.
  • Page 34 Site considerations Detail: A 30 - 40 SEE DETAIL A variable diameter - see graph as rigid a foundation as possible evenly distributed, applying more evenly distributed braces increases the stiffness Figure 2-14: Mast with three braces (measures in mm) (60 cm) 98-175666-A Chapter 2: Installation 2-14...
  • Page 35 Site considerations The following figure shows the maximum mast length and the mast/brace connection point over the outer mast diameter. Figure 2-15: Maximum mast length and connection point for a mast with three braces Example: The mast outer diameter is 150 mm. Then the mast length must be shorter than 240 cm and the brace/mast connection point is 56 cm from the top of the mast.
  • Page 36 Site considerations 2.2.4 Interference from radar, GPS/GNSS, L-band and other transmitters Do not place the antenna close to interfering signal sources or receivers. For Note allowed distances to other transmitters see Figure 2-18. It is recommended to test the total system by operating all equipment simultaneously and verifying that there is no interference.
  • Page 37 Site considerations X-band (~ 3 cm / 10 GHz) damage distance SAILOR XTR Ka ADU Radar d min. at 15° vertical power d min. at 60° vertical separation separation 0 – 10 kW 1.0 m 1.0 m 30 kW 2.0 m 1.0 m 50 kW 3.3 m...
  • Page 38 Site considerations If L-band antennas are installed on the same vessel, keep a minimum distance of 3 meters from the SAILOR XTR Ka ADU to the L-band antenna. The following figure shows the minimum recommended distance to other transmitters in the frequency range below 1000 MHz.
  • Page 39 Site considerations 2.2.6 Alternative ADU cable The allowed RF loss in the antenna cable is determined by the attenuators of the antenna. The electronic design guarantees that minimum 20 dB RF loss @ 1700 MHz (100 cm antenna) and 20 DB RF loss @ 1950 MHz (60 cm antenna) and maximum 35 dB RF loss @4450 MHZ (60 cm antenna) in the antenna cable will work, but typically an RF loss of about 25 dB will be within the limits of the cable calibration.
  • Page 40 Installation of the ADU (100 cm) 2.3 Installation of the ADU (100 cm) The following sections describe the installation and grounding of the ADU. The ADU is shipped fully assembled. Install it on the mast and attach the ADU cable. WARNING! Use a strong webbed sling with a belt to lift the ADU without damaging the radome.
  • Page 41 Installation of the ADU (100 cm) • Important: Maintain the vertical orientation of the ADU center line. • Always use all 4 bolts when installing the ADU. Figure 2-21: Free space for access to the service hatch You do not need to align the ADU with the bow-to-stern line of the ship. When configuring the SAILOR XTR Ka you make an automated azimuth calibration to obtain the correct azimuth of the ADU.
  • Page 42 Installation of the ADU (100 cm) 6. With a crane lift the ADU off the wooden platform and move it on top of the ADU mast. 7. Install the ADU on the mast flange with 4 M12 bolts and washers. Tightening torque value: 30 Nm.
  • Page 43 Installation of the ADU (100 cm) To open the service hatch Do as follows to open the service hatch: 1. With a Torx TX30 screw driver, loosen the 8 screws that keep the hatch in place. 2. Lower the service hatch and let it hang in the 2 strips Figure 2-25: Opening the service hatch 2.3.2 To ground the ADU Ground the ADU at the mounting bolts.
  • Page 44 WARNING! Use the lifting harness only to lift the antenna. Do not lift other objects or persons with the harness. The lifting harness (Cobham SATCOM part number TT 48-149056) is designed, tested and conforms to the requirements for lifting equipment in DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast).
  • Page 45 Installation of the ADU (60 cm) 2.4.1 To install the ADU Prerequisites • Ensure that the crane hook has a closing mechanism to prevent accidental slippage of the lifting straps. • Check for potential interference, read more in Interference from radar, GPS/GNSS, L- band and other transmitters on page 2-16.
  • Page 46 Installation of the ADU (60 cm) 7. Install the ADU on the mast flange with 4 M10 bolts and washers. Tightening torque value: 30 Nm. 8. Read carefully and follow instructions given in the next section on grounding. 9. Remove the harness as shown in the following figure: Figure 2-29: Removal of the harness 10.
  • Page 47 Installation of the ADU (60 cm) 2.4.2 To ground the ADU The ADU must be grounded using one of the mounting bolts. To ground the ADU do as follows: 1. Clean the metal underneath the head of at least one bolt of insulating protective coating and use a serrated washer to obtain a good ground connection.
  • Page 48 Installation of the BDU 2.5 Installation of the BDU The following sections describe the installation and grounding of the BDU. 2.5.1 To install the BDU To install the BDU, do as follows: 1. Slide the BDU into a 1U space in a 19” rack. 2.
  • Page 49 To connect the ADU, BDU and modem 2.6.2 To ground the modem 1. Make sure that the grounding requirements are met. See the appendix Ground and RF protection on page B-1 for details about grounding. Figure 2-32: Ground stud, GMU 2.7 To connect the ADU, BDU and modem The following sections show how to connect the ADU, BDU and the modem.
  • Page 50 Integration of a 3rd party IP device (100 cm) 2.8 Integration of a 3rd party IP device (100 cm) This section describes how to integrate a 3rd party device inside the antenna radome. The antenna has the following interfaces for the integration: •...
  • Page 51 Integration of a 3rd party IP device (100 cm) 2.8.3 Mechanical interface The antenna pedestal is prepared for mounting devices on the side of the pedestal. The mounting screw holes (M5x8mm) can support a special designed mounting bracket to support mounting of a 3rd party hardware device in the antenna. Figure 2-36: Mounting pattern on the pedestal Fasten the mounting bracket with 4.5 Nm Figure 2-37: Mounting pattern, measures...
  • Page 52 Power and startup 2.9 Power and startup 1. Connect power to the BDU. 2. Connect power to the VSAT modem. 3. Switch on the BDU. The unit starts up and goes through an initialization procedure: • Antenna POST pending • Antenna SW upload (If the software versions in the ADU and BDU are not the same, a software update is done during startup.) •...
  • Page 53 Chapter 3 Interfaces 3.1 Connector panel of the BDU Figure 3-1: BDU: connector panel 3.1.1 AC input connector Connect the power cable to the AC power connector. Outline (on the BDU) Voltage range 100–240 VAC Table 3-1: AC power connector 3.1.2 ADU connector There is just one cable from the BDU to the ADU.
  • Page 54 Connector panel of the BDU 3.1.3 Rx/Tx connectors for modem Connect the Rx and Tx channels of the modem to the Rx and Tx connectors of the BDU with the 2 supplied Rx/Tx cables (75 Ohm coax, F-F, 1 m). Outline Pin function (on the BDU)
  • Page 55 Connector panel of the BDU NMEA 0183 The NMEA 0183 connection supports IEC 61162-1 and IEC 61162-2. • IEC 61162-1, baud rate 4800, format 8N1. • IEC 61162-2, baud rate 38400, format 8N1. The baud rate is auto detected by the BDU, the user cannot configure this interface. Supported NMEA strings in order of priority: 1.
  • Page 56 Connector panel of the BDU 3.1.6 RS-232 RJ-45 connector Use the following connector to connect the BDU to the VSAT modem. Outline Signal Pin function RSSI 2 Analog (0 - 14 VDC) DTR/Rx Lock Modem Rx lock Receive data Ground Ground Transmit data DSR/TX Mute Tx mute RSSI 1 Analog (0 - 14 VDC)
  • Page 57 Interfaces of the modem 3.1.8 LAN connectors The BDU has four Ethernet connectors (type RJ-45), located at the back of the unit, for PC/laptops, routers, wireless access points. LAN port 5 is for service access at the front. Depending on the VSAT modem, one LAN connector may be used for modem control. The maximum cable length per connection is 100 m.
  • Page 58 Interfaces of the modem Outline Pin function (on the BDU) number Inner conductor: 50 MHz clock, Rx/Tx Outer conductor: GND (Shield) Table 3-9: F connector, Rx and Tx, outline and pin assignment 3.2.3 RS-232 and RS-422 connectors The modem has two RS-232 and one RS-422 connector for control information to and from the ACU.
  • Page 59 Interfaces of the modem 3.2.4 LAN connectors (8 + 2) The modem has 8 Ethernet connectors (type RJ45). Port 1 connects to the ACU and is used for modem control. The other ports are not used. The maximum cable length per connection is 100 m.
  • Page 60 Chapter 4 Setup of the antenna This chapter has the following sections: • Introduction to the web interface • Settings • Service • Keypad and menus of the BDU • Startup sequence The SAILOR XTR Ka system is not designed to be connected directly to the Important Internet.
  • Page 61 Introduction to the web interface 4.1 Introduction to the web interface Use the built-in web interface of the BDU to set up the SAILOR XTR Ka. Use a standard Internet browser. The menus are grouped in three sections: Dashboard, Settings and Service.
  • Page 62 Introduction to the web interface 2. Wait until the LEDs on the front plate of the BDU show that the system is ready to be configured. • Power LED: Green • Logon LED: Off • Fail/Pass LED: Flashing green, during power-on self test, after that steady green. 3.
  • Page 63 Introduction to the web interface Parameter Description Tracking RF frequency Antenna tracking frequency MODEM Model VSAT modem model used with the currently active VSAT profile RX locked status Shows whether the modem is in lock with the hub Status Status information received from modem. Not available for all models.
  • Page 64 Introduction to the web interface Top bar The top bar shows the host name and antenna model. It also has icons to report on the current status of the antenna. Underneath the top bar, to the right, the current antenna status is shown, e.g.
  • Page 65 Settings 4.2 Settings In this section you can define a VSAT profile, enter navigation input, set the blocking zones and define settings for added third-party equipment mounted in the antenna. You can also set passwords and user permissions. Furthermore you can access the installation wizard. 4.2.1 VSAT profiles In this section you set up the VSAT profile, including modem and satellite data.
  • Page 66 Settings 4.2.2 Modem types The following modem types are supported: • SAILOR GX Modem (GMU) • Generic Modem SAILOR GX Modem (GMU) To set up the modem type GX Modem, do as follows: Figure 4-8: Setup of SAILOR GX Modem 1.
  • Page 67 Settings Generic Modem To set up the modem type Generic, do as follows: Figure 4-9: Setup of Generic Modem Use the generic modem profile with any type of single beam VSAT modem. 1. Select the BUC reference. The setting is: TX 50 MHz 2.
  • Page 68 Settings • FCC (FCC §25.205): 5 degrees • ETSI (ETSI EN 302 340): The minimum elevation angle depends on the Tx bandwidth and the nominal power of the VSAT modem, see the table below. Bandwidth Nominal modem power Modem Power [dBm] Eirp@14.25 63.4 65.4...
  • Page 69 Settings 4.2.3 Network settings On this page you enter the host name and set up the network settings for the LAN ports of the BDU and the LAN ports of the ADU. Figure 4-10: Settings, Network page (example) Static IP or DHCP Client The default setting for LAN Port 3 is DHCP client.
  • Page 70 Settings static IP address. Then set the default gateway source to static and enter the IP address of the default gateway. To remove the default gateway set it to 0.0.0.0. Alternatively, if your DHCP server is able to provide a default gateway address and you have selected DHCP client above, then select the same LAN as your default gateway source.
  • Page 71 Settings Heading Description mode External Heading input from the vessel’s gyro compass (default). If there is no heading input due to failure, alarms are raised and the antenna continues in gyro-free mode. When heading input is available again and a new acquisition is made, alarms are cleared. Fixed Use this setting for an azimuth and cable calibration if there is no input from the vessel’s gyro compass and for permanent installations like...
  • Page 72 Settings 4.2.5 Operation in gyro-free mode Heading input: none If input from a gyro compass is not available, information from the GPS position is used when searching for a satellite. When the antenna does not have ship heading input from the vessel's gyro compass, the azimuth direction of the satellite is not known.
  • Page 73 Settings Tracking for satellite elevation above 75 degrees It is not possible to use a system without heading input from the vessel's gyro compass with satellites at an elevation of higher than 75 degrees because the system will not have the required polarization accuracy of the transmitted signal.
  • Page 74 Settings Without heading input and not fixed heading (Gyro-free) 1. A box search pattern is started and the positions with reception of RF power are checked for up to 10 seconds. If RX lock is detected for more than 20% of the time, the antenna goes to Tracking.
  • Page 75 Settings To set up a blocking zone, do as follows: 1. Select Settings > Blocking zones. 2. Select Active to enable the blocking zone and display it in the blocking map. Gray shading shows a blocking zone, red shading shows a No TX zone. 3.
  • Page 76 Settings Figure 4-16: Populated blocking map (example) 4.2.8 IoT & management On this page you can set up e-mail, remote syslog, SNMP, diagnostics and statistics reporting, and IoT. Figure 4-17: Settings, IoT & management (example) E-mail setup (secure e-mail) To send e-mails from the antenna you must set up some parameters. SMTP port numbers: •...
  • Page 77 Settings • STARTTLS to upgrade SMTP to Secure Socket Layer (SSL) or Transport Layer Security (TLS): IP port 587. Contact your IT department for the specific data. To set up e-mail, do the following: 1. Go to Settings > E-mail setup. 2.
  • Page 78 Settings • Dashboard and profile • Tracking receiver None of the SNMP values need to be polled more often than once a minute. Note Polling SNMP values more frequently will impact the performance of the SAILOR XTR Ka. To download the BDU MIB file directly, do as follows: 1.
  • Page 79 Settings Statistics report This report contains historical information from the SAILOR XTR Ka of up to 1 month. It is sent as a zipped attachment to an e-mail. The file format is a comma separated value file (csv). The report can then be processed in spreadsheet applications, e.g. Microsoft Excel. To set up sending a statistics report, do as follows: 1.
  • Page 80 Settings Parameter recorded Description Antenna.Azi (degree) Current antenna azimuth (sample, maximum and Antenna.Azi Max (degree) minimum value, range) for the sampling interval. See Antenna.Azi Min (degree) Figure 4-18: Statistics — how to read data for a Antenna.Azi Range (+/-degree) range. Antenna.Ele (+/-degree) Current antenna elevation (sample, maximum and Antenna.Ele Max (+/-degree)
  • Page 81 It is not possible to connect to the IoT hub or the data stream from external systems. Once the subscription has been purchased from Cobham SATCOM a list of IoT Keys will be provided. Each IoT key is unique and will be bound to the antenna the first time it connects.
  • Page 82 Settings 4.2.10 User administration In this section of the web interface you can configure the following administrative settings: • To change a password • To set up permissions for guest user To change a password On the page User administration you can change the password for admin or guest. You can bypass the admin password by pressing the left arrow key on the BDU for 5 seconds.
  • Page 83 Settings Figure 4-21: Permissions for guest users To set up the user permissions, do as follows: 1. From the left navigation pane, select Settings > User administration. 2. Click the pen icon for guest 3. For each item under Allow user to: select •...
  • Page 84 Settings 4.2.11 Installation wizard The installation wizard guides you through the necessary steps to set up the antenna. You start the installation wizard from the section Settings. Figure 4-22: Installation wizard 1. Enter the necessary data on each page and click Next. 2.
  • Page 85 Service 4.3 Service 4.3.1 Software In this section you can manage software versions, upload and save configurations and reset the SAILOR XTR Ka to factory default. Figure 4-23: Service - Software Upload The following items are required before the software can be updated: •...
  • Page 86 Service 5. The web interface opens directly with the Dashboard page. 6. Click Service in the top bar. The Software page is displayed. 7. Click Choose file and locate the new software file. 8. Click Upload. The upload procedure takes a couple of minutes. When done, the system automatically restarts with the new software version.
  • Page 87 Service 2. Click the button Choose file and locate the configuration file (.cfg file) you want to upload. Then click the button Upload. Factory default When resetting SAILOR XTR Ka to factory default, the following settings are deleted: • Passwords •...
  • Page 88 Service Figure 4-24: Service - Calibration Azimuth calibration Azimuth calibration is done toward a satellite of a known position. After finding the satellite, the system can calculate the azimuth offset of the ADU. The satellite and transponder properties for the calibration can be selected from a list of service profiles or supplied manually.
  • Page 89 Service Azimuth calibration (user controlled) 1. On the page SERVICE > Calibration, in the section Azimuth calibration (user controlled), select User defined in the Satellite drop down list. If you do not want to enter the satellite data on the calibration page you can Note select a dedicated satellite service profile for calibration and select it.
  • Page 90 Service The following table shows the error codes that might be displayed during a calibration. Error code Explanation The elevation of the selected satellite is too low. Select another satellite. The elevation of the selected satellite is too high. Select another satellite.
  • Page 91 Service Manual One Touch Commissioning (OTC) When the modem starts up for the first time it will automatically register with the BUC and perform P1dB compression on multiple frequencies and thereafter register with the network. During the P1dB compression the antenna will point away from the satellite and transmit on 950 MHz to 1950 MHz in 50 MHz steps.
  • Page 92 Service 6. Click Start. One Touch Commissioning takes place. When commissioning is completed the antenna will search for the I5 satellite with the highest elevation. 7. The antenna will find the satellite and the modem will perform the necessary steps to enter the network (software upgrades, if available).
  • Page 93 Service Figure 4-27: Service - Line up The ship must not move during the line-up procedure. Note To do the line up, do as follows: 1. Open an Internet browser and enter the IP address of the BDU (default IP address: http://192.168.0.1).
  • Page 94 Service 4.3.7 Events This page shows a detailed list of active events and notifications including the time of the first occurrence, ID and severity of the event message, and a short text describing the error. Events can be of the type WARNING or ERROR. The event time is UTC time. Active events are cleared from the event list when the error is cleared.
  • Page 95 Keypad and menus of the BDU Figure 4-29: Service - Support 4.4 Keypad and menus of the BDU 4.4.1 BDU display and keypad In the BDU display you can see the current state of the system. You can also see events (warnings, errors and information) and how the system has been configured.
  • Page 96 Keypad and menus of the BDU 8. TX: <External Un-mute> <Modem TX allowed> <ADU TX allowed> <TX pol> Read the TX status as follows: Upper case: Ok, lower case: Not ok, - unknown. <External Un-mute> = [U,u], <Modem TX allowed> = [m,M], <ADU TX allowed> = [a,A] <Tx pol>=[-,X,C] After 1 hour the display is dimmed to lowest intensity.
  • Page 97 Keypad and menus of the BDU ANTENNA Description POINTING ANTENNA STATE: Current state of the antenna, e.g. TRACKING ELEVATION: Current elevation angle of the antenna AZIMUTH: Current azimuth of the antenna, with reference to North POLARISATION RX POLARISATION: RHC or LHC read from connected VSAT modem TX POLARISATION: RHC or LHC read from connected VSAT modem GNSS LATITUDE: current latitude, read from GNSS module.
  • Page 98 Keypad and menus of the BDU NETWORK Description MASK 1 Current netmask for LAN 1. PORT 2 IP Current IP address for LAN 2. MASK 2 Current netmask for LAN 2. PORT 3 IP (LAN 3) Current IP address of the SAILOR 1000 XTR Ka 4.5W web interface (default: 192.168.0.1).
  • Page 99 Startup sequence Example: EVENT 1/4*: This is the first event out of a list of 4 and there has been a change in the list. EVENT 1/4 will always be shown, the * indicates that there has been a change. 4.5 Startup sequence Once the system is configured and a VSAT profile is active, the startup sequence is as follows:...
  • Page 100 Chapter 5 Installation check lists Use the following sections to verify that the system is ready for customer delivery. 5.1 Installation check list: Antenna Step Task Further information Done Check that the antenna is free of See Obstructions (ADU obstructions. shadowing) on page 2-4.
  • Page 101 Installation check list: BDU, connectors and wiring 5.2 Installation check list: BDU, connectors and wiring Verification and further Step Task Done information Check that the BDU is grounded See To ground the BDU on correctly, using the mounting bolts and page 2-28 and washers.
  • Page 102 Installation check list: Functional test in harbor 5.3 Installation check list: Functional test in harbor Step Task Further information Done Check that the antenna is tracking The logon LED in the BDU display the satellite must be steady green and the display shows: TRACKING.
  • Page 103 Chapter 6 Service This chapter has the following sections: • Built-in test and LEDs • Removal and replacement of the BDU • Removal and replacement of ADU modules • Troubleshooting basics • Returning units for repair 6.1 Built-in test and LEDs The ADU and the BDU have a Built-In Test Equipment (BITE) function in order to make fault diagnostics easy during service and installation.
  • Page 104 Table 6-2: LEDs on the BDU 6.2 Removal and replacement of the BDU There are no parts in the BDU that you can remove or replace. Contact your Cobham SATCOM service partner for repair or replacement. 6.3 Removal and replacement of ADU modules All replacement of modules must be done by a Cobham SATCOM service partner.
  • Page 105 Troubleshooting basics 6.4 Troubleshooting basics 6.4.1 Overview This section describes an initial check of the primary functions of the SAILOR XTR Ka system, and provides some guidelines for troubleshooting. Generally, if a fault occurs without any obvious reason, it is always recommended to observe the LEDs and the BDU display showing the active events.
  • Page 106 COBHAM SYNC PARTNER PORTAL, which may help you solve the problem. Your dealer, installer or Cobham SATCOM partner will assist you whether the need is user training, technical support, arranging on-site repair or sending the product for repair. Your dealer, installer or Cobham SATCOM partner will also take care of any warranty issue.
  • Page 107 Appendix A Technical specifications This appendix has the following sections: • Specifications (100 cm antenna) • Specifications (60 cm antenna) • Patents • Outline drawings 98-175666-A...
  • Page 108 Specifications (100 cm antenna) A.1 Specifications (100 cm antenna) SYSTEM SPECIFICATIONS Frequency band Ka-band (Inmarsat GX-R2) Reflector size 103 cm / 40.6” Type approvals Inmarsat Certification Compliant with CE (Maritime), ETSI, FCC System power supply range 100-240 VAC, 50-60 Hz Total system power consumption 4.5W: 135W typ.
  • Page 109 Specifications (100 cm antenna) Compass safe distance 1.5 m / 59” to EN60945 Maintenance, scheduled None Maintenance, unscheduled All modules, motor, RF parts and belts are replaceable through service hatch Built In Test Power On Self-Test, Person Activated Self-Test and Continuous Monitoring w.
  • Page 110 Specifications (60 cm antenna) A.2 Specifications (60 cm antenna) SPECIFICATIONS Frequency band Ka-Band (Inmarsat GX-R2) Reflector size 65 cm / 25.5” Type Approvals Inmarsat Certification Compliant with CE (Maritime), ETSI, FCC System power supply range 100 - 240 VAC, 50-60 Hz Total system power consumption 4.5W: 135 W typical, 185 W max (excl.
  • Page 111 Specifications (60 cm antenna) BELOW DECK UNIT (BDU) Dimensions 1U 19” rack mount HxWxD: 4.4 x 48 x 33 cm / 1.73” x 18.9” x 13” Weight 3.6 kg / 8 lb Temperature (ambient) Operational: -25°C to +55°C / -13°F to +131°F Storage: -40°C to +85°C / -40°F to +185°F Humidity EN 60945 Protected, 95% (non-condensing)
  • Page 112 Patents A.3 Patents The patents listed below apply to SAILOR 1000 XTR Ka 4.5W and SAILOR 1000 XTR Ka 9W Patent application number Description 11749202.5; 10-2013- An assembly comprising a movable and 7008607; 13/819,621 brakable/dampable part and a method for braking a movable part PCT/EP2012/063849 Combined antennas without switch...
  • Page 113 Outline drawings A.4 Outline drawings A.4.1 ADU SAILOR 1000 XTR Figure A-1: Outline drawing: ADU (1 m) 98-175666-A Appendix A: Technical specifications...
  • Page 114 Outline drawings A.4.2 ADU SAILOR 600 XTR Figure A-2: Outline drawing: ADU (60 cm) 98-175666-A Chapter A: Technical specifications...
  • Page 115 Outline drawings A.4.3 BDU Figure A-3: Outline drawing: BDU 98-175666-A Chapter A: Technical specifications...
  • Page 116 Outline drawings A.4.4 GMU Figure A-4: Outline drawing: BDU 98-175666-A Chapter A: Technical specifications A-10...
  • Page 117 Appendix B Dual antenna solution This appendix has the following sections: • Introduction • Installation of the dual antenna solution • Configuration of the dual antenna solution • Flow chart for installation of the dual antenna solution B.1 Introduction The SAILOR XTR Ka Dual antenna solution has the following features: •...
  • Page 118 Installation of the dual antenna solution RX (L-Band) BUC M&C (RS-232) ACU M&C (Ethernet) Keyline (RS-422) RX combiner (Master) RX (L-Band) TX (L-Band) ADU (Master) BUC M&C (RS-232) ACU M&C (Ethernet) Modem Keyline (RS-422) TX (L-Band) RX (L-Band) TX Splitter Keyline (RS-422) (Slave) TX (L-Band)
  • Page 119 Installation of the dual antenna solution B.2.2 Installation To install the dual antennas, do as follows: 1. Install the master ADU, BDU, the RX combiner and the VSAT modem. 2. Install the slave ADU, BDU and the TX splitter. 3. Provide vessel heading input to the master BDU and slave BDU. 4.
  • Page 120 Configuration of the dual antenna solution B.3 Configuration of the dual antenna solution B.3.1 Overview The master antenna VSAT profile is configured the same way as a single antenna system. The master is additionally enabled to be a dual antenna master system and will always listen for a slave connection.
  • Page 121 Configuration of the dual antenna solution B.3.2 To configure the Master BDU The configuration of the master BDU depends on which ports are used and how your network has been configured. Before you enable dual mode, set up the master and the slave to be on the Important same subnet but with different IP addresses.
  • Page 122 Configuration of the dual antenna solution 4. If LAN port 1 is used for the slave: Set the IP address and netmask for the slave BDU to match the subnet of the master BDU. In other cases configure on the page Settings > Network.
  • Page 123 Configuration of the dual antenna solution Figure B-6: Dual-antenna mode, blocking zones — azimuth and elevation B.3.5 To make an OTC for dual antenna systems Prerequisites Do not power up the GMU at this point in time. Important 1. Make an azimuth calibration with both antenna systems (master and slave) using manual azimuth calibration mode and one of the GX satellites, Make sure you have line-of-sight..
  • Page 124 Flow chart for installation of the dual antenna solution B.4 Flow chart for installation of the dual antenna solution Figure B-7: Flow chart for dual antenna installation Appendix B: Dual antenna solution 98-175666-A...
  • Page 125 Dual antenna splitter cable B.5 Dual antenna splitter cable Figure B-8: Splitter cable 98-175666-A Chapter B: Dual antenna solution...
  • Page 126 Appendix C Miscellaneous C.1 Performance optimization for blockage C.1.1 Encountering blockage, configured with multiple satellites. Definition of blockage In most VSAT installations the VSAT antenna is installed in a position with areas of blockage. Blockage is often caused by the vessel's masts, stacks and other equipment installed on board.
  • Page 127 Performance optimization for blockage Minimum elevation angle One safe way of getting optimum performance under the current conditions is to switch to a satellite in view as fast as possible. This is done by having well defined satellite parameters in the VSAT modem configuration. It is the VSAT modem that has the task of selecting the correct satellite, and since the VSAT modem is only concerned about the satellite visibility at the current geographic position, it is very important to enter the minimum elevation of a satellite at which a stable link can be established.
  • Page 128 Appendix D Command line interface D.1 Supported connection modes After you have done the initial configuration and connected the SAILOR XTR Ka to your network, you can use SSH to configure the SAILOR XTR Ka. You can also set up VSAT modem parameters.
  • Page 129 List of commands Access to the SAILOR VSAT system system is protected by a user name and password. This is the same user name and password that is used in the web interface under ADMINISTRATION. The interface is on the standard Telnet port 23 or SSH port 22. Use any LAN port and corresponding IP address of the BDU (except LAN 2 on GX/Ka BDU).
  • Page 130 List of commands • help • navigation • status • system • test • iothub D.2.1 antenna_data Command Description Shows detailed information of this specific command. antenna_data Shows current antenna type. Example output: antenna_data type UCLI:/$ antenna_data type System: 7509D Type: Oem: inmarsat...
  • Page 131 List of commands D.2.4 demo Command Description Shows detailed information of this specific command. demo Starts a demo pattern where the antenna will turn azimuth, demo start elevation and cross elevation until it receives the command demo stop. Stops the antenna demo pattern. demo stop Resets the antenna to angle 0.
  • Page 132 List of commands Command Description Shows the sub commands, unit and description for the help demo command demo Shows the sub commands, unit and description for the help dual command dual antenna antenna Shows the sub commands, unit and description for the help exit command exit Table D-8: UCLI command: help (Continued)
  • Page 133 List of commands D.2.10 system Command Description Shows detailed information of this specific command. system system restart Sends a command to the BDU to restart the system instantaneously. It makes a power-on self test and then points to the last used satellite. Shows the software version, part names and serial numbers of the system info SAILOR 1000 XTR Ka 4.5W.
  • Page 134 Appendix E Grounding and RF protection E.1 Introduction to grounding E.1.1 Reasons for grounding Grounding the SAILOR 1000 XTR Ka 4.5W system is required for at least two reasons: • Safety: Lightning protection of persons and equipment. • Protection: ESD (Electro Static Discharge) protection of equipment. E.1.2 Safety First of all grounding of the system is required for safety reasons.
  • Page 135 Grounding Recommendations E.2 Grounding Recommendations E.2.1 To ground the BDU The BDU should be grounded to the ship/hull. For this purpose you may use a short ADU cable and a grounding kit. Further, the BDU must be grounded at its grounding stud in order to ensure proper grounding if the short ADU cable is disconnected.
  • Page 136 Grounding Recommendations contact to the hull. Use serrated washers when securing the mounting bolts and seal the joint with protective coating to avoid corrosion. Antenna bottom Mounting base M12 bolt Serrated washer (stainless steel) (stainless steel) Figure E-2: Grounding the ADU For optimum grounding use the mounting bolt located closest Note to the ADU cable plate, see To ground the ADU on page 2-23.
  • Page 137 Grounding Recommendations To ground the ADU For optimum grounding use the mounting bolt located closest Note to the ADU cable plate, see To ground the ADU on page 2-23. Terminal grounded at the hull (recommended) In this case the ADU is grounded to the ship via one (or more) of its mounting bolts. Make sure to remove painting, dirt, grease etc.
  • Page 138 The BDU should preferably be grounded with the short ADU cable and a grounding kit (available from Cobham SATCOM). Further, the BDU must be grounded at its grounding stud in order to ensure a proper grounding if the short ADU cable is disconnected.
  • Page 139 Grounding Recommendations The ground connection must be established at a dedicated RF ground (either capacitive or electrical coupled). Bear in mind that the ADU ground connection is to be Important made at the same electrical ground potential as the BDU (see To ground the ADU). To ground the ADU If the mounting base of the ADU is electrically connected to any other ground potential than the BDU (e.g.
  • Page 140 Grounding Recommendations below. The crimp terminals must be a marine approved type e.g. the DuraSeal series from Raychem. Antenna: Terminal: Figure E-6: Separate ground cable Ground cable - connection Mount the ground cable close to and parallel to the shielded coax cable thus minimizing ground loop problems.
  • Page 141 Grounding Recommendations Isolation of the ADU from the mounting base In cases where the ADU is to be isolated from the mounting base, shoulder bushings and washers (accessories) must be used as illustrated below. Please note that the isolation has to be implemented on all four mounting bolts (including the bolt securing the ground cable).
  • Page 142 Jumper cable for grounding E.3 Jumper cable for grounding Figure E-9: Jumper cable for grounding (specifications) 98-175666-A Appendix E: Grounding and RF protection...
  • Page 143 Appendix F Event messages F.1 Overview The SAILOR XTR Ka detects events during • POST (Power On Self Test) – a self test performed at every power-up. • Self test – started in the web interface • CM (Continuous Monitoring) – automatically performed while the system is in operation.
  • Page 144 List of events F.2 List of events (241121) Module Type Description Explanation 08061-0 ADM WARNING VMU linux shell The specified password (root) for the satellite password modem is not accepted by the modem. (!T,!G,!S) 08062-0 ADM WARNING VMU debug shell The specified password (user) for the satellite password modem is not accepted by the modem.
  • Page 145 List of events Module Type Description Explanation 08077-0 ADM WARNING BUC LO frequency The satellite modem provided an invalid BUC LO invalid frequency. A default BUC LO frequency is assumed based on antenna type. To remove this warning re- configure the modem to provide a valid BUC LO frequency.
  • Page 146 List of events Module Type Description Explanation 08085-0 ADM WARNING Radome temp too The temperature in the radome is too high. high 08086-0 ADM WARNING GPIO Tx mute active Tx has been muted from GPIO on the BDU. (!T) 08087-0 ADM WARNING Temperature Temperature too high.
  • Page 147 List of events Module Type Description Explanation 08523-0 ADM ERROR Ele axis calibration Elevation axis zero reference or end stops not found at expected locations. Check belt, zero reference module, and end stops. Info: See 08521- 08524-0 ADM ERROR Pol axis calibration Polarisation axis zero reference or end stops not found at expected locations.
  • Page 148 List of events Module Type Description Explanation 08547-0 ADM ERROR VIM PLL lock The PLL of the VIM is out of lock. Check the 10 MHz reference signal. 08548-0 ADM WARNING VIM tuner lock The PLL of the second receiver (DVB) is out of lock. Check the 10 MHz reference signal.
  • Page 149 List of events Module Type Description Explanation 0855C-0 ADM WARNING Pol cal. limits Check limits of the calibration result for the polarisation axis are exceeded. Pointing performance may be degraded. Info: See 08559-0. (!T,!G) 0855D-0 ADM WARNING ISM warning The ISM has temporarily observed an unusual situation for temperature or voltage.
  • Page 150 List of events Module Type Description Explanation 08842-0 ADM WARNING GSC demodulator The GSC demodulator has reported an error. (!V,!T) 08843-0 ADM WARNING DVBS demodulator The DVBS demodulator cannot be initialised and loaded correctly. (!V,!T) 08844-0 ADM ERROR BUC voltage out of The BUC voltage is out of range.
  • Page 151 List of events Module Type Description Explanation 08A04-0 ADM WARNING iDirect modem The ACU detected a warning/error in the iDirect modem. Log into the modem for more information. Info: 0x00000001: Temperature error 0x00000002: Test error 0x00000004: Fan error (!V,!T) 08A05-0 ADM WARNING GX Core Module The GX core module heater is active.
  • Page 152 List of events Module Type Description Explanation 0A107-0 Antenna ERROR ISCM Power good Internal PSU error. 0A108-0 Antenna ERROR ISCM Prod data Internal production data invalid. 0A180-0 Antenna WARNING ISCM Fan error BUC fan failure. Check fan movement. 0A181-0 Antenna ERROR ISCM No response No communication with ISCM.
  • Page 153 List of events Module Type Description Explanation 0A401-0 Antenna ERROR Ele Motor ZRM No zero reference found. Check from motor to ZRM and free movement of the antenna. 0A480-0 Antenna ERROR Ele Motor Driver fault Driver could not move antenna. Check free movement of the antenna.
  • Page 154 List of events Module Type Description Explanation 0B064-0 APSM WARNING APSM EBUS Temperature too high. (!T,!S) temperature warning 0B065-0 APSM ERROR APSM EBUS Temperature too high. EBUS shut down. (!T,!S) temperature failure 0B066-0 APSM WARNING APSM LNB Temperature too high. (!T,!S) temperature warning 0B067-0 APSM ERROR...
  • Page 155 List of events Module Type Description Explanation 0B094-0 APSM INFO APSM Main Over Voltage too high. (!T,!S) voltage protection 0B0A0-0 APSM ERROR APSM No communication with APSM. Check internal Communication error connections in ACM. (!T,!S) 0B0A1-0 APSM ERROR BDCM No communication with BDCM. Check main Communication error antenna cable.
  • Page 156 Appendix G Inmarsat GX satellites This appendix contains examples of satellite data for azimuth calibration. The following figure shows the coverage map of the GX service. Global Xpress network available Extendable Global Xpress over at least 99% of this area coverage via steerable beams 90°...
  • Page 157 Appendix H Approvals H.1 CE (RED) 98-175666-A...
  • Page 158 Inmarsat type approval H.2 Inmarsat type approval 98-175666-A Appendix H: Approvals...
  • Page 159 Glossary Glossary Antenna Control Unit ACU Digital Module. A main processor board in the ACU. Antenna Diversity Solution AIMO Antenna Interface Module APSM Antenna Power Supply Module BDCM BDU Control Module BEIDOU Chinese satellite navigation system BIMO BDU Interface MOdule BITE Built-In Test Equipment Continuous Monitoring...
  • Page 160 Glossary Local Area Network Light Emitting Diode LGPL Lesser General Public License Left Hand Circular LHCP Left Hand Circular Polarization Low Noise Block Long-Term Evolution (also called 4G) Management Information Base Network IDentification NMEA National Marine Electronics Association (standard) Object Identifier, in the context of the Simple Network Management Protocol (SNMP), consists of the object identifier for an object in a Management Information Base (MIB).
  • Page 161 Index Index BDU display description 4-36 access BDU rack version limit 4-23 installing 2-28 ACMAntenna Control Module 4-11 BEIDOU 4-12 acquisition BITE test 6-1 gyro-free 4-15 blockage search pattern 4-14 performance optimization C-1 search pattern, inclined orbit 4-14 blocking zones time 4-15 azimuth 2-5 administrator...
  • Page 162 Index command line interface D-1 display config D-3 BDU, description 4-36 demo D-4 distance dual antenna D-4 antenna to radar 2-16 exit D-4 DNS setup 4-10 help D-2 drainage of antenna 2-18 modem D-5 drawing status D-5 ACU rack version A-9 supported commands D-2 ADU A-7 system D-6...
  • Page 163 Index elevation angle 4-8 import configuration 4-27 4-28 Features 1-2 inclined orbit fiberglass hulls search pattern for acquisition 4-14 grounding E-5 inclined orbit satellites 4-13 fire wall 4-1 installation fixed heading 4-12 BDU 2-28 fixed TX gain 4-34 Interfaces 3-1 flange thickness 2-7 interference 2-16 flatness 2-7...
  • Page 164 Index mast 2 braces 2-11 2-12 obstructions 3 braces 2-10 2-12 distance and size 2-4 design 2-6 one touch commissioning 4-31 flange thickness 2-7 opening antenna 2-23 flatness 2-7 options foundation 2-6 order number 1-9 gusset plates 2-7 order number height 2-6 options 1-9 steel type 2-6...
  • Page 165 Index RF interference SNMP 4-18 recommendations E-1 community string 4-18 RF loss SNMP traps ADU cable, maximum 2-22 setup 4-18 roll period software update limitations 2-4 automatic rollback 4-27 mounting height 2-4 recover 4-27 ship 2-4 software version rollback verify 4-27 software upload 4-27 specifications A-1 RS-232...
  • Page 166 Index upload configuration 4-27 4-28 user CLI D-1 user permissions 4-24 setup 4-23 verification tracking mode 6-3 VMU connector 3-5 VSAT profiles 4-6 warning messages F-1 warranty 6-4 web interface connect 4-2 LAN connector 3-5 modem 4-32 web mmi LAN connector 3-5 weight mast 2-11 Wiring 3-1...
  • Page 167 98-175666-A www.cobhamsatcom.com...

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