COBHAM SAILOR 100 GX Technical Manual
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COBHAM SAILOR 100 GX Technical Manual

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  • Page 1 SAILOR 100 GX Technical manual...
  • Page 2 SW Technology/GPL Compliance, Cobham SATCOM (Thrane & Thrane A/S), Lundtoftegaardsvej 93D 2800 Lyngby DENMARK Write "source for product SAILOR 100 GX" in the memo line of your payment. This offer is valid to anyone in receipt of this information. http://www.cobham.com/about-cobham/communications-and-connectivity/about-us/satcom/free-and- open-source-software-(foss).aspx 99-145912-A...
  • Page 3 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 4 Power supply The voltage range for the SAILOR 100 GX ADU and ACU is 20 – 32 VDC. The Above Deck Unit is powered by the ACU. If a 24 VDC power bus is not available, an external 115/230 VAC to 28 VDC power supply can be used, for example a SAILOR 6080 Power Supply.
  • Page 5 Record of Revisions Rev. Description Release Date Initials Original document 26 June 2015 99-145912-A...
  • Page 6 99-145912-A...

  • Page 7: Table Of Contents

    Satellite type approvals ....................2-8 2.1.6 Service activation ........................2-8 Part numbers and options ..................2-9 2.2.1 Applicable model and part numbers ................2-9 2.2.2 Options for SAILOR 100 GX ...................2-9 Chapter 3 Installation What’s in the box ......................3-1 3.1.1 To unpack ..........................3-1 3.1.2 Initial inspection ........................3-2...
  • Page 8 5.2.2 Power cable of the GMU ....................5-3 Power up ..........................5-3 5.3.1 To connect the power cable to the ACU and GMU ...........5-3 5.3.2 Power-up procedure ......................5-4 5.3.3 Initialisation steps in daily use ..................5-4 5.3.4 SAILOR 100 GX operational ...................5-5 99-145912-A...
  • Page 9 Table of contents Chapter 6 Configuration Introduction to the built-in web interface ..........6-1 6.1.1 Overview ..........................6-1 6.1.2 Connecting to the web interface ................6-1 Calibration ..........................6-4 6.2.1 Service profile for calibration ..................6-4 6.2.2 Heading input ........................6-6 6.2.3 Azimuth calibration ......................6-9 6.2.4 Cable calibration .......................6-11 6.2.5 Manual One Touch Commissioning (BUC calibration) ........
  • Page 10 Table of contents Chapter 8 Service & maintenance To get support ........................8-2 8.1.1 Help desk and diagnostic report ..................8-2 Software update ........................8-5 8.2.1 Prerequisites ..........................8-5 8.2.2 Software update (ADU, ACU) ..................8-5 8.2.3 Software update (GMU) ....................8-7 Satellite profiles and VSAT modem profiles ..........8-8 8.3.1 Satellite profiles ........................8-8 8.3.2...
  • Page 11 Diagnostics report for troubleshooting ..............8-72 8.9.4 Troubleshooting .......................8-76 8.9.5 X-elevation bearing test ....................8-77 8.10 To return units for repair ..................8-78 Appendix A Technical specifications SAILOR 100 GX system components ..............A-1 A.1.1 General specifications .......................A-1 A.1.2 ADU ............................A-2 A.1.3 ACU ............................A-4 A.1.4 GMU ............................A-5...
  • Page 12 Table of contents Separate ground cable ....................B-11 B.6.1 To construct a ground cable ..................B-11 B.6.2 Ground cable - connection ..................B-12 B.6.3 Isolation of the ADU from the mounting base ..........B-12 RF interference ........................ B-13 Jumper cable for grounding ................... B-14 Appendix C System messages Event messages –...

  • Page 13: About This Manual

    About this manual Intended readers This is an installation and service manual for the SAILOR 100 GX system, intended for installers of the system and service personnel. Personnel installing or servicing the system must be properly trained and authorized by Cobham SATCOM.

  • Page 14: Typography

    Typography Typography In this manual, typography is used as indicated below: Bold is used for the following purposes: • To emphasize words. Example: “Do not touch the antenna”. • To indicate what the user should select in the user interface. Example: “Select SETTINGS >...

  • Page 15: Chapter 2 Introduction

    To protect the ADU the built-in DC motors act as brakes during transport and when the ADU is not powered. You can access the SAILOR 100 GX remotely and make in-depth performance analysis using the built-in web interface.
  • Page 16 SAILOR 100 GX system The following figure shows the SAILOR 100 GX system. Above Deck Unit (ADU) Antenna Control Unit (ACU) GX Modem Unit (GMU) Figure 2-2: ADU, ACU and GMU SAILOR 100 GX features  Single 50 Ohm coax cable for the ADU.

  • Page 17: Above Deck Unit (Adu)

    SAILOR 100 GX system 2.1.2 Above Deck Unit (ADU) The SAILOR 100 GX ADU is a 103 cm stabilized tracking antenna, consisting of a suspended antenna with a standard global RF configuration. It is stabilized by heavy duty vibration dampers in 3-axis (plus skew) and can be used in environments with elevations of -25°...
  • Page 18 SAILOR 100 GX system Modules in the SAILOR 100 GX ADU Figure 2-4: Above Deck Unit modules 1/2 1. GPS module. 2. VSAT Interface Module (VIM2). 3. Pedestal Control Module (PCM). 4. Service switch. In switch-off position the DC Motor Driver modules and the BUC are turned off for safe conditions during service and repair.
  • Page 19 SAILOR 100 GX system 7. Zero Reference Module (x3) (ZRM) (not visible on photo). (2 in the figure above, 1 in the figure below) 8. DC-Motor Driver Module for elevation (on the bottom) (DDM). 9. Elevation motor and encoder (not visible).

  • Page 20: Antenna Control Unit (Acu)

    SAILOR 100 GX system Four lifting brackets (included in the delivery) and reuse of packing material help getting the ADU safely into place. Satellite profile parameters are entered in the built-in web server of the ACU, using a PC. The system configuration is saved in two modules, there is no loss of data at repair.
  • Page 21 SAILOR 100 GX system You can do remote diagnostics and service with the ACU. Its built-in test equipment constantly checks the device for proper functioning. It performs POST (Power On Self Test) and you can request a PAST (Person Activated Self Test). Continuous Monitoring (CM) is also available. BITE error codes can be read out in the web interface and in the display of the ACU.

  • Page 22: Gx Modem Unit (Gmu)

    For a list of satellite type approvals see Appendix E, Approvals. 2.1.6 Service activation Before you can start using the SAILOR 100 GX, you need to activate the system for the GX service. Contact your service provider for activation. Chapter 2: Introduction...

  • Page 23: Part Numbers And Options

    Antenna cable 50 m N-Conn (not mounted), male/male 407090A-925 Pigtail Cable 1.25 m, N-Conn, female/male 406080A-005 19” Rack mount kit for SAILOR 6080 AC/DC Power Supply Table 2-2: Part numbers for options of the SAILOR 100 GX system 99-145912-A Chapter 2: Introduction...
  • Page 24 Part numbers and options 2-10 Chapter 2: Introduction 99-145912-A...

  • Page 25: Installation

    Chapter 3 Installation This chapter has the following sections: • What’s in the box • Site preparation • Installation of the ADU • Installation of the ACU • Installation of the GMU • To connect the ADU, ACU and GMU What’s in the box 3.1.1 To unpack...

  • Page 26: Initial Inspection

    What’s in the box 3.1.2 Initial inspection Inspect the shipping cartons and wooden box immediately upon receipt for evidence of damage during transport. If the shipping material is severely damaged or water stained, request that the carrier's agent be present when opening the cartons and wooden box. Save all box packing material for future use.

  • Page 27: Site Preparation

    1. Mount the ADU on stiffened structures with a minimum of exposure to vibrations. You do not have to align the ADU with the bow-to-stern line of the ship. When configuring the SAILOR 100 GX system, the azimuth calibration provides the correct azimuth of the ADU. Painting the radome Customers may wish to paint the radome in order to match the vessel’s...

  • Page 28: Obstructions (Adu Shadowing)

    Site preparation 3.2.2 Obstructions (ADU shadowing) The ADU is stabilized in 3-axis (plus skew) and can be used in environments with elevations of -25° to + 125° to allow for continuous pointing even in heavy sea conditions. The ADU beam is approximately 1 m in diameter for the first 30 m from the ADU.

  • Page 29: Blocking Zones With Azimuth And Elevation

    Site preparation 3.2.3 Blocking zones with azimuth and elevation Your installation may require that you set up blocking zones for the ADU, i.e. areas where the ADU will not transmit and areas where transmit power is potentially dangerous for persons frequently being in these zones.

  • Page 30: Safe Access To The Adu (Radiation Hazard)

    Site preparation 3.2.4 Safe access to the ADU (radiation hazard) The ADU radiates up to 54.5 dBW EIRP. This translates to a minimum safety distance of 30 m from the ADU while it is transmitting, based on a radiation level of 10 W/m MICROWAVE RADIATION NO PERSONNEL within safety distance of 30 m, based on 10 W/m...

  • Page 31: Ship Motion And Offset From The Ship's Motion Centre

    Site preparation 3.2.5 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 3-1.

  • Page 32: Mast Foundation And Height

    Site preparation 3.2.6 Mast foundation and height The ADU mast must be designed to carry the weight of the ADU (126 kg), plus the weight of the mast flange. The mast must also be able to withstand on-board vibrations and wind speeds up to 110 knots on the radome, even in icing conditions.
  • Page 33 Site preparation CAUTION! Avoid sharp edges where the flange is in direct contact with the radome. Round all edges as much as possible to avoid damaging the surface of the radome. 3. Allow sufficient space so the nut is free of the welded seam and there is room for tools (min.
  • Page 34 Site preparation Mast length and diameter The placement of the ADU must ensure a rigid structural connection to the hull or structure of the ship. Parts of the ship with heavy resonant vibrations are not suitable places for the ADU. A small platform or short mast shall provide rigid support for the ADU fastening bolts and a rigid interface to the ship.
  • Page 35 Site preparation - always consider the environment and characteristics of the ship before deciding on the mast dimensions. Mast without Max. free mast Outer Wall Weight braces length (steel), (m) Diameter (mm) Thickness (mm) (kg/m) 24.0 26.5 30.2 32.7 Table 3-2: Mast dimensions without braces a.
  • Page 36 Site preparation Max. free Outer Thickness Outer Wall mast Diameter Mast with 2 braces Diameter Thickness length (steel), for brace brace (mm) (mm) (mm) (mm) Table 3-4: Mast dimensions with 2 braces Make sure that there is sufficient space underneath the ADU to open the service hatch.

  • Page 37: Interference From Radar, Gps And Other Transmitters

    Mount the ADU as far away as possible from the ship’s radar and high power radio transmitters, because they may compromise the ADU performance. RF emission from radars might actually damage the ADU. The SAILOR 100 GX ADU itself may also interfere with other radio systems. Radar...
  • Page 38 Even at distances greater than “d min.” in the previous section the radar might still be able to degrade the performance of the SAILOR 100 GX system. The presence of one or more S or X-band radars within a radius up to 100 m may cause a minor degradation of the Ka-band connection.
  • Page 39 Site preparation extra degradation due to the radar(s) could cause poor connection quality. The presence of S-band radar(s) is unlikely to cause any performance degradation – as long as the minimum distances (d min.) listed in the previous section are applied. It is strongly recommended that interference-free operation is verified experimentally before the installation is finalized.

  • Page 40: Condensation, Water Intrusion And Deposits

    Site preparation 3.2.8 Condensation, water intrusion and deposits In some weather conditions there may occur condensation inside the radome. The drain tube is designed to lead any water away from inside the radome. Observe the following guidelines for condensation and water intrusion: 1.

  • Page 41: Installation Of The Adu

    Installation of the ADU Installation of the ADU The following sections describe the installation and grounding of the ACU. The ADU is shipped fully assembled. You have to 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 42: To Install The Adu

    Installation of the ADU 3.3.1 To install the ADU Prerequisites • Check for potential interference, read more in Interference from radar, GPS and other transmitters on page 3-13. • Install the ADU at a location where vibrations are limited to a minimum.
  • Page 43 Installation of the ADU 7. Install the ADU on the mast flange with 4 M12 bolts and washers. Read carefully and follow instructions given in To ground the ADU on page B-4. Tightening torque value: 30 Nm. Always use all 4 bolts when installing the ADU. 8.
  • Page 44 Installation of the ADU page A-9 for a more detailed drawing how to connect the N- connector on the ADU. Protection plate N connector Figure 3-18: Connecting the ADU cable 11. Ensure that the connector assembly is properly protected against seawater and corrosion.

  • Page 45: To Open And Remove The Service Hatch

    Installation of the ADU 3.3.2 To open and remove the service hatch Through the service hatch you can access the antenna modules. You can remove the hatch for better mobility when servicing the antenna. Do as follows to open and remove the service hatch: 1.

  • Page 46: To Ground The Adu

    Installation of the ADU 3.3.3 To ground the ADU The ADU must be grounded using 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 2.

  • Page 47: Alternative Adu Cable

    Installation of the ADU 3.3.4 Alternative ADU cable The allowed RF loss in the antenna cable must be maximum 20 dB RF loss @ 1950 MHz and maximum 35 dB RF loss @ 4450 MHz. You can verify the cable attenuation margin with the cable calibration, see Cable calibration on page 6-11 for more details.

  • Page 48: Installation Of The Acu

    Installation of the ACU Installation of the ACU The following sections describe the installation and grounding of the ACU. 3.4.1 To install the ACU A cable relief bracket is already mounted when receiving the ACU. The cable relief is a simple system to secure cables with cable strips. It offers a number of holders to which you can secure the cables from the ACU.

  • Page 49: Installation Of The Gmu

    Installation of the GMU Installation of the GMU The following sections describe the installation and how to ground the GMU. 3.5.1 To install the GMU To install the GMU, do as follows: 1. Slide the GMU into a 1U space in a 19” rack, preferably directly below or above the ACU.

  • Page 50: To Connect The Adu, Acu And Gmu

    To connect the ADU, ACU and GMU To connect the ADU, ACU and GMU The following figure shows how to connect the ADU, ACU and the GMU. AC power DC power Service port for control PC Figure 3-25: Connection between ADU, ACU and GMU 1.

  • Page 51: Interfaces Of The Acu

    Chapter 4 Interfaces This chapter has in the following sections: • Interfaces of the ACU • Interfaces of the GMU Interfaces of the ACU 4.1.1 LEDs, display, keypad and connectors The following figure shows the LEDs, display and the keypad of the ACU. For an explanation of the texts in the display see ACU display and keypad on page 6-39.

  • Page 52: Dc Input Connector

    Interfaces of the ACU 4.1.2 DC Input connector The ACU must be provided with DC power, for example by using the SAILOR 6080 AC/DC Power Supply or 24 VDC from the vessel’s power supply. DC input: Female plug (Weidmuller, Part number 1930050000) for wires up to AWG10/6 mm (included in the delivery).

  • Page 53: Rx In And Tx Out Connectors

    Interfaces of the ACU Do not use TNC connectors on the ADU antenna cable or Important on pigtails. TNC connectors cannot carry the DC current for operating the ADU. 4.1.4 Rx In and Tx Out connectors The ACU has an Rx Out and a Tx In connector. Use these connectors to connect the ACU to the GMU.

  • Page 54: Rs-232 And Rs-422 Connectors

    Interfaces of the ACU NMEA 0183 The NMEA 0183 connection supports EN 61162-1 (baud rate 4800, format 8N1) and EN 61162-2 (baud rate 38400, format 8N1). The ACU detects the baud rate automatically, you cannot configure this interface. Supported NMEA sentences: •...

  • Page 55: Lan1 - 4 Connectors

    LAN connector of the ACU for system control. 4. Use Port 4 (network 3) to connect the SAILOR 100 GX to the vessel’s For more details about the LAN networks see To configure the LAN network on page 6-24.

  • Page 56: Interfaces Of The Gmu

    Interfaces of the GMU Interfaces of the GMU The following sections describe the connectors of the GMU and how to connect to the ACU, power and other equipment. 4.2.1 Connector panel The following figure shows the connector panel of the GMU. Figure 4-4: Connector panel of the GMU 4.2.2 Rx In and Tx Out connectors...
  • Page 57 Interfaces of the GMU 4.2.3 RS-232 and RS-422 connectors The GMU has two RS-232 and one RS-422 connector for control information to and from the ACU. See section To connect the ADU, ACU and GMU on page 3-26 for details how to connect the ACU to the GMU. Outline (on the GMU) Pin function Not connected...

  • Page 58: Rx In And Tx Out Connectors

    Interfaces of the GMU 4.2.4 LAN connectors (8 + 2) The GMU 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. The Ethernet cable type must be CAT5, shielded.

  • Page 59: Power And Startup

    Chapter 5 Power and startup This chapter has the following sections: • Power source • Power cables • Power up Power source The ACU is powered with DC power. There are different options for the power supply: • The 24 VDC ship supply provides power for the ACU. •...
  • Page 60 Power cables To measure the ship’s source impedance To measure the ship’s source impedance do as follows: 1. Select a power outlet from the ship’s 24 VDC system. 2. Measure the voltage without load (R.var disconnected). 3. Set the current to e.g. 1 A by adjusting R.var. 4.

  • Page 61: Power Cable Of The Gmu

    Power up To calculate the maximum cable extension, do as follows: 1. Measure the source impedance in the ship installation as shown in Figure 5-1. 2. Find the resistance per meter (Rwire) for the cable type you are going to use. 4 mm /AWG 11: 4.8 mOhm/m at 55°C 6 mm...

  • Page 62: Power-Up Procedure

    • READY This may take some time (up to a couple of minutes). 5. The SAILOR 100 GX is ready to be calibrated (for first time power up) or receive data from the GMU (when in normal operation). The LEDs Power and Fail/Pass are steady green, the LED Logon is off.

  • Page 63: Sailor 100 Gx Operational

    Power up 5.3.4 SAILOR 100 GX operational When the display shows TRACKING. MDM: NETOK and the LED Logon is steady green the system is operational. Figure 5-4: ACU display, system operational 99-145912-A Chapter 5: Power and startup...
  • Page 64 Power up Chapter 5: Power and startup 99-145912-A...

  • Page 65: Configuration

    Overview Use the built-in web interface (installation of software is not necessary) of the SAILOR 100 GX ACU to make a full configuration of the SAILOR 100 GX. You can use a standard Internet browser. For quick start instructions see Calibration on page 6-4.
  • Page 66 Introduction to the built-in web interface Figure 6-1: LAN 3 connector used for configuring the SAILOR 100 GX If you want to use another LAN port to access the web interface you must configure it according to your network requirements. See To configure the LAN network on page 6-24 for more information.
  • Page 67 Introduction to the built-in web interface Figure 6-3: Dashboard For a detailed introduction to the web interface see Overview and dashboard on page 6-16. 99-145912-A Chapter 6: Configuration...

  • Page 68: Calibration

    Important Switch on the GMU after the cable calibration. Before the SAILOR 100 GX can be used you must select a heading input setting in order to make an azimuth and cable calibration. The azimuth calibration is required in order to determine the offset of the ADU zero direction to the bow-to-stern line of the ship.
  • Page 69 Calibration Figure 6-4: Service profile for calibration 7. Enter the data for the satellite that you want to use as a calibration reference. Note the following calibration requirements: Elevation angle: 5 – 70 degrees. Not allowed for calibration: Inclined orbit. Satellite identifier: GSC, NID, Orbital position (DVB-S, DVB-S2) Satellite Position Frequency...

  • Page 70: Heading Input

    Calibration 6.2.2 Heading input Access the page for heading and calibration through SERVICE > Calibration. Figure 6-5: Web interface: SERVICE, Calibration (example) If you do not want to enter the satellite data on the Note calibration page you can select a dedicated satellite service profile for calibration and select it.
  • Page 71 Calibration Heading input Description 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. See also About operation in gyro-free mode on page 6-14.
  • Page 72 Calibration 3. The antenna checks each stored position for up to 10 seconds. If RX lock is detected for more than 20% of the time, the antenna goes to Tracking. With heading input or fixed heading and Inclined Orbit Satellite 1.

  • Page 73: Azimuth Calibration

    Calibration Acquisition times Inclination Activity 0° 1° 2° 3° 4° Initial search 10 s 10 s 10 s 10 s 10 s Scan box pattern 5 s 10 s 15 s 25 s 30 s Validate result 10 - 30 s 10 - 30 s 10 - 30 s 10 - 30 s...
  • Page 74 Calibration User controlled azimuth calibration with user defined input 1. On the page SERVICE > Calibration, in the section Azimuth calibration (user controlled), select User defined in the Satellite drop down list. 2. Type in the longitude of the satellite. See Table 6-1 on page 6-5 The calibration function is not able to verify the Important correctness or precision of the supplied longitude.

  • Page 75: Cable Calibration

    Calibration Error codes during a calibration 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. The calibration values could not be saved.

  • Page 76: Manual One Touch Commissioning (Buc Calibration)

    Calibration 4. When commissioning is completed, test all subscribed services. When input from the vessel’s gyro compass is not Important available: Change the heading input setting from Fixed to None at Heading – Input. Fixed heading is not allowed for sailing vessels! 6.2.5 Manual One Touch Commissioning (BUC calibration) When the GMU starts up for the first time it will automatically register...
  • Page 77 Calibration 4. Type the user name admin (default) and the password iDirect (default). Figure 6-11: Unified web interface of the Core Module 5. In the menu Commissioning click One Touch Commissioning. 6. Click Start. Once commissioning is completed the antenna will search for the I5 satellite with the highest elevation.

  • Page 78: About Operation In Gyro-Free Mode

    Calibration 6.2.6 About 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 79: Fixed Tx If Principle

    6.2.7 Fixed TX IF principle The SAILOR 100 GX uses a TX IF gain concept. After calibration it provides a fixed average gain from the TX-port of the ACU to the input of the BUC. Advantages of the fixed TX IF gain principle are: •...

  • Page 80: Configuration With The Web Interface

    Configuration with the web interface Configuration with the web interface 6.3.1 Overview and dashboard Topics in the web interface Use the site map to get an overview over the existing menus, submenus and topics. You can click on each menu in the site map to go directly to the page or display the respective submenu.
  • Page 81 Configuration with the web interface Figure 6-13: Web interface: DASHBOARD 1. The navigation pane holds the main menu. Clicking an item in the menu opens a submenu in the navigation pane or a new page in the contents section. 2. The signal status field shows the tracking signal strength of the antenna.
  • Page 82 Configuration with the web interface Icon Explanation An event is active. Click the icon to see a list of active events. For explanations of the event messages, see Event messages – overview on page C-1. Note that this icon will remain in the icon bar as long as the event is active.
  • Page 83 Configuration with the web interface Information fields on the Dashboard DASHBOARD Description System status Current status of the SAILOR 100 GX Examples: Not ready (waiting for input from GNSS, e.g. GPS) Ready (waiting for data from the modem or no satellite profile selected)
  • Page 84 Description BUC TX On or Off. Shows if the SAILOR 100 GX has enabled the BUC or not. It is the same TX ON/TX OFF as shown in the display of the ACU, see ACU display and keypad on page 6-39.
  • Page 85 Configuration with the web interface To use a satellite profile you must activate it, go to Satellite profiles and click Activate at the desired satellite profile. Figure 6-14: Satellite profile with generic GX modem 99-145912-A Chapter 6: Configuration 6-21...

  • Page 86: To Set Up Blocking Zones (Rx And Tx)

    Configuration with the web interface 6.3.2 To set up blocking zones (RX and TX) You can define blocking zones, i.e. NO TX and RX zones, enter azimuth values and elevation angles for each blocking zone. To enable a blocking zone you must select Active. Figure 6-15: Web interface: SETTINGS, Blocking zones —...
  • Page 87 Configuration with the web interface 3. Enter start and stop azimuth value in degrees for the blocking zone. Values allowed: 0 to 360 degrees. Enter clockwise. Figure 6-16: Blocking zone, example: 315 - 45 degrees Figure 6-17: Blocking zone, example: 45 - 315 degrees 4.

  • Page 88: To Configure The Lan Network

    If any ports of the SAILOR 100 GX are exposed to the Internet you must change the default passwords as anyone with access and malicious intent can render the SAILOR 100 GX inoperable.
  • Page 89 Configuration with the web interface Figure 6-18: Web interface: SETTINGS, Network (default settings) Make sure that the networks do not use IP address ranges that overlap. Important Make the necessary changes on this page and click Apply. Sections Preferred use NETWORK Host The host name is used for identifying the ACU in local networks and in name...
  • Page 90 Configuration with the web interface Sections Preferred use LAN Port 2 LAN port 2 is used for Internet access or Inmarsat Network Service Device (NSD). LAN Port 3 LAN port 3 is dedicated as the service port. By default this port has the IP address http://192.168.0.1;...

  • Page 91: E-Mail Setup

    Configuration with the web interface The default gateway can be set as a 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 92: To Send Statistics Reports

    SAILOR 100 GX can send a statistics report at fixed intervals through an external Internet connection. This report contains historical information from the SAILOR 100 GX up to 1 month. It is sent as a zipped attachment to an e-mail address. The file format is a comma- separated value file (csv).
  • Page 93 ACU serial number ADU SN ADU serial number SW ver. Software version System type SAILOR 100 GX Table 6-12: Statistics report, header record Parameter recorded Description UTC. (s) UTC in seconds and date format for the data set. UTC (YYYY-MM-DD hh:mm) RSSI.Av...
  • Page 94 Configuration with the web interface Parameter recorded Description Carrier rf.rx (GHz) Rx frequency of carrier for this record. Carrier rf.tx (GHz) Tx frequency of carrier for this record. Pol.rx Current Rx and Tx polarisation modes Pol.tx Rx Lock (%) Rx locked and logon time, in percent, for the sampling Logon (%) interval.

  • Page 95: To Send A Diagnostics Report

    Configuration with the web interface Figure 6-22: Statistics report (example) 6.3.6 To send a diagnostics report You can send automatically generated diagnostic reports at fixed intervals. The diagnostic report contains information from the ADU and ACU that are relevant for the service personnel during troubleshooting. To set up sending a statistics report, do as follows: 1.

  • Page 96: Upload

    Configuration with the web interface 6.3.7 Upload For uploading new software to the SAILOR 100 GX see Software update on page 8-5. 6.3.8 Administration In this section of the web interface you can configure the following administrative settings: • To access the administration settings (user name, password) •...
  • Page 97 Configuration with the web interface Do as follows: 1. After entering the administrator user name and password in the ADMINISTRATION page, locate the section Change administrator logon. Figure 6-24: Web interface: Administration, change administrator logon and password 2. Type in the new password and retype it on the next line. 3.
  • Page 98 2. Click Logoff. To set up user permissions (guest login) You can manage user access to certain functions of the SAILOR 100 GX system. You can allow or deny users that are not administrators (user name: guest, password: guest) access to certain functions and make these pages read-only.
  • Page 99 Configuration with the web interface Figure 6-26: Web interface: ADMINISTRATION, User permissions 2. For each item under ALLOW USERS TO: select • Yes to allow access • No to block access to the settings. Then the pages are read-only, changes cannot be made by non-administrator users. Item Description Change network...
  • Page 100 Configuration with the web interface To import and export a system configuration If you need to reuse a configuration in another SAILOR 100 GX system, you can save the current configuration to a file, which can then be loaded into another SAILOR 100 GX. You can also use this feature as backup.
  • Page 101 Configuration with the web interface • All modem profiles • Blocking zones • Heading settings • Azimuth adjustment • Network setup • User permissions • ACU display: brightness setting To reset to factory default settings, do as follows: 1. From the left navigation pane, select ADMINISTRATION > Factory default.
  • Page 102 Configuration with the web interface 2. In the drop-down box select one of the three options: • Level 0 – Power cycle of the GMU • Diagnostic Test Mode – Only connection to the GMU is the serial RS-232 interface, all other connections are shut down. •...

  • Page 103: Keypad And Menus Of The Acu

    Use the keypad to navigate through the menu tree. Signal strength Figure 6-30: Display and keypad of the ACU (example) 1. Current status of the SAILOR 100 GX: NOT READY (Waiting for input from GNSS, e.g. GPS) READY (no satellite profile selected)

  • Page 104: Navigating The Menus

    Keypad and menus of the ACU 9. TX: <Extern mute> <Modem TX> <ADU TX> <TX pol> <Extern mute> = [X,x] <Modem TX> = [m,M] <ADU TX> = [a,A] <Tx pol>=[-,H,V,L,R] After 1 hour the display is dimmed to lowest intensity. Press any key to light up the display.
  • Page 105 Description menu MAIN View with current status of the SAILOR 100 GX. Example when logged on to the satellite: This view is displayed after a time out of 10 minutes. Press any key (except left arrow) to enter the menu at MAIN.
  • Page 106 Keypad and menus of the ACU Top-level Description menu NETWORK IP addresses and netmasks of the LAN connectors of the ACU and the management mask. SATELLITE Current satellite information. This information is selected using the web interface. EVENTS System events. Active events are shown as: X ACTIVE EVENTS in the MAIN display.
  • Page 107 Current IP address for LAN 1 MASK 1 Current netmask for LAN 1 PORT 3 IP (LAN 3) Current IP address of the SAILOR 100 GX web interface (default: http://192.168.0.1) MASK 3 (LAN 3) Current netmask of the SAILOR 100 GX web interface (default: 255.255.255.0)

  • Page 108: Brightness Of The Display

    Keypad and menus of the ACU SATELLITE menu Description RX FREQUENCY Ka band receiving frequency of the active satellite, auto-selected by modem LNB LO 18.25 GHz, system hardware. TX FREQUENCY Transmission frequency, auto-selected by modem BUC LO 28.05 GHz, system hardware LNB LO HIGH Current LNB Local Oscillator frequency, high band (GHz), selected in the satellite profile...

  • Page 109: Reset Of The Acu And Adu

    Keypad and menus of the ACU 6.4.5 Reset of the ACU and ADU To reset the ACU and ADU do the following: 1. Press and hold until the ACU display shuts down and the ACU and ADU reboots. Figure 6-32: Reset the system 2.

  • Page 110: Snmp Support

    SNMP is always enabled on all Ethernet interfaces. The SNMP community string is public. The SAILOR 100 GX offers via SNMP most of the data that are available from the DASHBOARD web pages. Detailed documentation about supported OIDs can be found in the SAILOR 100 GX MIB file.
  • Page 111 Chapter 7 Installation check Now that you have installed the system, you can test it to verify it is ready for customer delivery. Follow the check lists below to test the system for proper operation. • Installation check list: Antenna •...

  • Page 112: Installation Check List: Antenna

    Installation check list: Antenna Installation check list: Antenna Step Task Further information Done Check that the antenna is free of obstructions. See Obstructions (ADU shadowing) on page 3-4. Make sure there is sufficient space for access See To install the ADU on page 3-18. through the service hatch.

  • Page 113: Installation Check List: Acu And Gmu, Connectors And Wiring

    Installation check list: ACU and GMU, connectors and wiring Installation check list: ACU and GMU, connectors and wiring Step Task Verification and further information Done Check that the ACU is grounded correctly, See To ground the ACU on page 3-24 using the mounting bolts and washers.

  • Page 114: Installation Check List: Functional Test In Harbor

    Installation check list: Functional test in harbor Installation check list: Functional test in harbor Step Task Further information Done Check that the antenna is tracking The logon LED in the ACU display must be the satellite steady green and the display must show: TRACKING.

  • Page 115: Service & Maintenance

    Chapter 8 Service & maintenance This chapter has the following sections: • To get support • Software update • Satellite profiles and VSAT modem profiles • Status signalling with LEDs and status messages • Removal and replacement of the ACU •...

  • Page 116: To Get Support

    You can download the MIB file. At Legal notice you can see the licence text for the source code of the parts of the SAILOR 100 GX software that falls under free and open source software. If you need help with ACU or ADU related issues call your service provider.
  • Page 117 List of ADU events on page C-2 and List of ACU events on page C-8. 8..1.1.4 Self test You can start a self test of the SAILOR 100 GX ADU and ACU. 1. Click Self test in the HELPDESK page. 99-145912-A Chapter 8: Service & maintenance...
  • Page 118 8..1.1.5 Reset to factory defaults You can reset the SAILOR 100 GX ADU and ACU to factory defaults. See To reset to factory default - ADU and ACU on page 6-36. Warning! Reset to factory default will delete all...

  • Page 119: Software Update

    ACU display as ADU SW UPLOAD. To make a software update, do as follows: 1. Power up the SAILOR 100 GX system, i.e. switch on the ACU. Wait until the SAILOR logo has disappeared from the ACU display. 2. Connect a PC to LAN interface 3 (Service port, standard Ethernet) of the ACU or to the front LAN connector of the ACU.
  • Page 120 Software update 3. Open your Internet browser and enter the IP address of the ACU. The default IP address is http://192.168.0.1. 4. Type in the user name admin and the password 1234 to access the Dashboard. 5. The web interface shows the DASHBOARD page. 6.

  • Page 121: Software Update (Gmu)

    Software update 8..2.2.2 To verify the software update (ADU and ACU) The software version can be viewed in the DASHBOARD window of the web interface. After completing the software update procedure, the ACU will perform a POST (Power On Self Test). When the POST has finished, the green Pass/Fail LED on the front of the ACU must become steadily green.

  • Page 122: Satellite Profiles And Vsat Modem Profiles

    Satellite profiles and VSAT modem profiles Satellite profiles and VSAT modem profiles 8.3.1 Satellite profiles A satellite profile with the GX Modem is already set up at the factory. You may add a satellite profile with the generic modem for troubleshooting purposes.

  • Page 123: Vsat Modem Profiles

    Satellite profiles and VSAT modem profiles 2. Enter or edit the Satellite profile name. It is helpful to assign a name containing the location where Note the Satellite profile is to be used (e.g. Gulf of Mexico or North Sea) and possibly the provider. 3.
  • Page 124 Satellite profiles and VSAT modem profiles Figure 8-8: Web interface: SETTINGS, VSAT modem profile – supported modems 2. Fill in a VSAT modem profile name of your own choice. 3. Select one of the supported VSAT modems from the drop down list. Generic modem: If you have a modem that is not included in the list, select the generic modem.

  • Page 125: Status Signalling With Leds And Status Messages

    For details on error messages after a POST or a self test see Event list on page 8-3. 8..4.1.2 Means of signalling The SAILOR 100 GX provides various methods for signalling the system status. LEDs on the front panel of the ACU are used to signal: • Power on/off • Logon •...

  • Page 126: Leds Of The Adu Modules

    Status signalling with LEDs and status messages 8.4.2 LEDs of the ADU modules Each ADU module has a Power and a Service LED. Behaviour Description Power Steady green Power supply OK No power Service Steady green Module ok, application running. Flashing green Waiting for upload Flashing red/green...

  • Page 127: Leds Of The Gmu

    Status signalling with LEDs and status messages Behaviour Description Fail/Pass Steady red A fault which prevents operation is present in the system (ACU, ADU, MODEM). Flashing A Power On Self Test (POST) or Person green Activated Self Test (PAST) in progress. The current status is displayed.

  • Page 128: Removal And Replacement Of The Acu

    Removal and replacement of the ACU Removal and replacement of the ACU There are no parts in the ACU that you can remove or replace. Contact your Cobham SATCOM service partner for further repair or replacement. 8-14 Chapter 8: Service & maintenance...

  • Page 129: Removal And Replacement Of Adu Modules

    Removal and replacement of ADU modules 8.6.1 Overview All replacement of modules must be carried out by a Cobham SATCOM service partner. The figure below shows the modules and their position. Some modules are equipped with LEDs for status information and troubleshooting.
  • Page 130 Removal and replacement of ADU modules 1. GPS module. This module is positioned near the service switch at the bottom of the pedestal. It converts the GPS satellite signals into current position data. 2. VSAT Interface Module (VIM2). The purpose of the VIM2 is to interface between the ADU coaxial cable carrying several signals (DC, modem, RX IF, L-band TX) and the cable to the LNB/BUC, and the PCM.
  • Page 131 Removal and replacement of ADU modules 3. Pedestal Control Module (PCM). Figure 8-11: PCM – Block diagram The PCM will - based on several inputs - control the position of the parabolic reflector and the polarization angle of the polarisation mechanism assembly via 3 brush less DC-motors and a stepper motor.
  • Page 132 Removal and replacement of ADU modules In switch-off position the DC Motor Driver modules (DDM), the BCM and the BUC are turned off for safe conditions during service and repair. The switch must be in on position for normal ADU operation. The switch only controls movements and prevents any transmission.
  • Page 133 Removal and replacement of ADU modules • Connection to the BLDCM, and delivering the required phase current to the motor. • Decoding the HALL-sensor input from the Zero Reference Module (ZRM). • Decoding the input from the Optical Rotary Encoder (ORE). •...
  • Page 134 Removal and replacement of ADU modules band IF output is routed to the VSAT Interface Module (VIM2) located on the ADU's azimuth pedestal. 13.Polarizer. The PMM provides power and communicates with the BUC. Control signals forwarded by VIM2 from BDU via coax cable are demodulated and sent to BUC for correct functionality.
  • Page 135 Removal and replacement of ADU modules • High stability and accuracy 3 axis accelerometer and angular rate sensor. • Prepared for wide range 3 axis accelerometer. • Calibration of sensor offset, gain, and misalignment over temperature (stored in non-volatile memory). •...
  • Page 136 Removal and replacement of ADU modules to be ported from the stationary platform to the azimuth rotating part of the ADU. This is done via the rotary joint. 20.Feed horn. The feeder horn carries the mirror centred of the dish and in the correct distance.
  • Page 137 Removal and replacement of ADU modules The S-bus is as a single master/multi slave half-duplex UART link, mastered by the PCM module (5 Mbit/s). The S-Bus master and slave modules are - by means of shielded DB9 cables - connected in a chain in the following order; PCM - DDM(azimuth) - DDM(x-elevation) - DDM(elevation) - ISM - BCM.

  • Page 138: To Replace The Gps Module

    Removal and replacement of ADU modules 8.6.2 To replace the GPS module Bottom view Top view Figure 8-18: GPS module The GPS Module is equipped with a receiver antenna (on top side) receiving the signals transmitted from the GPS satellites (low orbit), typical 10-12 are visible above the horizon.
  • Page 139 Removal and replacement of ADU modules 4. Disconnect the connector located on the bottom side of the GPS PCB. Figure 8-20: Connector for GPS PCB 5. Loosen the 4x4 mm Allen screws (thread size M5). Figure 8-21: Screws on GPS module 6.

  • Page 140: To Replace The Vsat Interface Module (Vim2)

    Removal and replacement of ADU modules 8.6.3 To replace the VSAT Interface Module (VIM2) To replace the VIM2, do as follows: 1. Open the service hatch. Tools needed: 2. Switch off the power to the antenna on the service switch. •...
  • Page 141 Removal and replacement of ADU modules 7. Disconnect the N-connector at the top (A) and the one at the bottom of the VIM (B), the SUB-D-connector (C), then the SMA connector (D) at the bottom of the VIM2. A (2 Nm) D (1 Nm) B (2 Nm) C (manual)

  • Page 142: To Replace The Dc-Motor Driver Module (Ddm)

    Removal and replacement of ADU modules Figure 8-26: VIM2 module for Ka antenna After installing a new VIM you must update the calibration Important data. For instructions see To update VIM2/PCM calibration data on page 8-67. 8.6.4 To replace the DC-Motor Driver Module (DDM) The ADU is equipped with three (3) DDMs for the axes: •...
  • Page 143 Removal and replacement of ADU modules Power LED (green) Service LED (green or red) Figure 8-27: DC-Motor Driver Module (DDM) for Cross Elevation For step-by-step instructions see: • To replace the Cross Elevation DDM on page 8-29 • To replace the Elevation DDM on page 8-30 •...
  • Page 144 Removal and replacement of ADU modules Figure 8-28: Replacing the DDM — remove connectors 5. Remove the 4x4 mm Allen screws (thread size M5) (visible when the connectors are removed) and remove the Cross Elevation DDM. To insert a new DDM follow the instructions above in reverse order. 8..6.4.2 To replace the Elevation DDM To remove the Elevation DDM, do as follows:...
  • Page 145 Removal and replacement of ADU modules Figure 8-29: Elevation DDM, connectors 5. Remove the 4x4 mm Allen screws (thread size M5) (visible when the connectors are removed) and remove the Elevation DDM. To insert a new Elevation DDM follow the instructions above in reverse order.

  • Page 146: To Replace The Buc Control Module (Bcm)

    Removal and replacement of ADU modules 5. Disconnect the 3 connectors at the right of the Azimuth DDM, then the 2 SUB-D connectors at the left of the Azimuth DDM. Note that two connectors are identical. Mark them so you Note know where each connector belongs to (e.g.
  • Page 147 Removal and replacement of ADU modules 5. Disconnect the 4 connectors from the BCM (mark them to avoid mistakes). Figure 8-32: Connectors at the BCM 6. Remove the 4x4 mm Allen screws (thread size M5). Figure 8-33: Cable connection from the cable wrap If access for some reason is limited, remove the Ka RF-pack, see section TBD.

  • Page 148: To Replace The Pedestal Control Module (Pcm)

    Removal and replacement of ADU modules 8.6.6 To replace the Pedestal Control Module (PCM) The PCM controls the antenna dish and the polarization mechanism assembly with the three DC motors and a step motor. Communication between the PCM and ACU is done via the VIM2. The VIM2 is also controlled by the PCM via a parallel interface cable.

  • Page 149: To Replace Motor And Encoder

    Removal and replacement of ADU modules To insert a new PCM follow the instructions above in reverse order. After installing a new PCM you must update the Important calibration data. For instructions see To update VIM2/PCM calibration data on page 8-67. 8.6.7 To replace motor and encoder The ADU is equipped with three DC-motors, two of which are identical,...
  • Page 150 Removal and replacement of ADU modules 8..6.7.1 To replace the Elevation Motor and Encoder To remove the Elevation Motor and Encoder, do as follows: Tools needed: 1. Open the service hatch.Switch off the power to the antenna on the service switch. •...
  • Page 151 Removal and replacement of ADU modules 3. Disconnect the 8-pin connector and the 6-pin connector (colored wires) from the Elevation DDM. Figure 8-37: Elevation DDM, disconnect 2 connectors 4. Loosen the 4x4 mm Allen screws from the motor assembly. Figure 8-38: Elevation motor and encoder, loosen the screws for the motor assembly 5.
  • Page 152 Removal and replacement of ADU modules 2. Tighten the 4x4 mm Allen screws from the motor assembly. Figure 8-39: Elevation motor and encoder, tighten the screws for the motor assembly 8..6.7.2 To replace the Azimuth Motor To remove the Azimuth Motor, do as follows: Tools needed: 1.
  • Page 153 Removal and replacement of ADU modules 6. Loosen the 15x4 mm Allen screws (the 3 Allen screws on top are longer than the rest) on the cover over the azimuth drive modules, and remove the cover (lift and slide). L=35 mm L=35 mm L=35 mm Figure 8-41: Azimuth motor, remove cover 7.
  • Page 154 Removal and replacement of ADU modules 8. Adjust the belt-tension screw to middle position. Figure 8-43: Azimuth motor, adjust belt tension 9. Disconnect the 8-pin connector from the Azimuth DDM. Figure 8-44: Azimuth DDM, disconnect connector 10.Loosen the 4x4 mm Allen screws (thread size M5) from the motor assembly.
  • Page 155 Removal and replacement of ADU modules To insert a new Azimuth Motor follow the instructions above in reverse order — while observing the following guidelines: 1. String the Azimuth belt around the pulley of the motor assembly and around the belt tensioner. 2.
  • Page 156 Removal and replacement of ADU modules 4. Tighten the belt tension device by tightening the 4x4 mm Allen screws (thread size M5). Figure 8-48: Azimuth motor, tighten the belt tensioner 5. Check the tension of the belt again (90-100 Hz). If needed, repeat the tension adjustment.
  • Page 157 Removal and replacement of ADU modules 6. Loosen the 15x4 mm Allen screws (the 3 Allen screws on top are longer than the rest) on the cover over the azimuth drive modules, and remove the cover (lift and slide). L=35 mm L=35 mm L=35 mm Figure 8-49: Azimuth encoder, remove cover 7.
  • Page 158 Removal and replacement of ADU modules 8. Loosen the belt tension device by loosening the 4x4 mm Allen screws (thread size M5)and slide out the Azimuth Encoder. Figure 8-51: Azimuth encoder, remove 9. Adjust the belt-tension screw to middle position. Figure 8-52: Azimuth encoder, adjust belt tension To insert a new Azimuth encoder follow the instructions above in reverse order while observing the following guidelines:...
  • Page 159 Removal and replacement of ADU modules 3. Tighten the belt tension device by tightening the 4x4 mm Allen screws (thread size M5). Figure 8-54: Azimuth motor, tighten the belt tensioner 4. Check the tension of the belt again (90-100 Hz). If needed, repeat the tension adjustment.
  • Page 160 Removal and replacement of ADU modules 6. Disconnect the 3 cables at the top of the Cross Elevation DDM. Figure 8-55: Replacement of X-Elevation Motor & Encoder 1 7. Loosen the Cross-Elevation Drive belt tension/adjustment screw. Figure 8-56: X-Elevation Motor & Encoder — belt tension/adjustment screw 8-46 Chapter 8: Service &...
  • Page 161 Removal and replacement of ADU modules 8. Loosen the 4x4 mm Allen screws (thread size M5) of the motor assembly. Figure 8-57: X Elevation motor assembly, 4 Allen screws 9. Lift the complete X Elevation Motor & Encoder assembly free, in the key holes, from the pedestal and remove it.

  • Page 162: To Replace The Drive Belts

    Removal and replacement of ADU modules 3. Now tighten the 4x4 Allen screws (thread size M5) of the Cross Elevation Motor & Encoder assembly. Figure 8-60: X Elevation motor assembly, tighten screws 4. Check the tension of the belt again (80-100 Hz). If needed, repeat the tension adjustment.
  • Page 163 Removal and replacement of ADU modules 6. Remove the cable drum by removing the 4x4 mm Allen screws (thread size M5) and leave the cable drum hanging in the cables. Figure 8-61: Removing the cable drum 7. Remove the Cross Elevation Drive Belt. To insert a new X Elevation Drive Belt the instructions above in reverse order —...
  • Page 164 Removal and replacement of ADU modules 8..6.8.2 To replace the Elevation Drive Belt To remove the Elevation Drive Belt, do as follows: Tools needed: 1. Open the service hatch. 2. Switch off the power to the antenna on the service switch. •...
  • Page 165 Removal and replacement of ADU modules 6. Loosen the 15x4 mm Allen screws (the 3 Allen screws on top are longer than the rest) on the cover over the azimuth drive modules, and remove the cover (lift and slide). L=35 mm L=35 mm L=35 mm Figure 8-62: Azimuth drive modules, remove cover 7.
  • Page 166 Removal and replacement of ADU modules 9. Adjust the belt-tension screw to middle position. Figure 8-64: Azimuth drive belt, adjust belt tension 10.Remove the RF connector (N-type, finger nut) from the Rotary Joint. Step 9 Step 8 Figure 8-65: Getting access to the azimuth drive wheel 11.Loosen the 4x4 mm Allen screws (thread size M5) from the cover plate over the azimuth drive wheel.
  • Page 167 Removal and replacement of ADU modules 13.Remove the Azimuth Drive Belt. Figure 8-66: Azimuth Drive Belt To insert a new Azimuth Drive Belt follow the instructions above in reverse order while observing the following guidelines: Follow the instructions in To replace the Azimuth Motor on page 8-38. 99-145912-A Chapter 8: Service &...

  • Page 168: To Replace The Zero Reference Module (Zrm)

    Removal and replacement of ADU modules 8.6.9 To replace the Zero Reference Module (ZRM) The ADU has the following identical ZRMs, one for each drive wheel (each axes): • X Elevation ZRM • Elevation ZRM • Azimuth ZRM Figure 8-67: Location of the Zero Reference Modules (ZRM) The ZRM has a Hall sensor that detects a zero point (small magnet, mounted on the drive wheel).
  • Page 169 Removal and replacement of ADU modules 8..6.9.1 To replace the X Elevation ZRM To remove the X Elevation ZRM, do as follows: Tools needed: 1. Open the service hatch. 2. Switch off the power to the antenna on the service switch. •...
  • Page 170 Removal and replacement of ADU modules 7. Through the two holes (above the X Elevation DDM) in the pedestal loosen the 2x4 mm Allen screws. Figure 8-70: X Elevation ZRM, slide out 8. Slide out the X Elevation ZRM. To insert a new X Elevation ZRM follow the instructions above in reverse order.
  • Page 171 Removal and replacement of ADU modules 6. Disconnect the connector from the Elevation ZRM. Figure 8-71: Elevation ZRM, disconnect connector 7. Loosen the 2x4 mm Allen screws. Figure 8-72: Elevation ZRM, remove screws 8. Slide out the Elevation ZRM. To insert a new Elevation ZRM follow the instructions above in reverse order.
  • Page 172 Removal and replacement of ADU modules 8..6.9.3 To replace the Azimuth ZRM To remove the Azimuth ZRM, do as follows: Tools needed: 1. Open the service hatch. 2. Switch off the power to the antenna on the service switch. • TX20 3.
  • Page 173 Removal and replacement of ADU modules 7. Disconnect the connector from the Azimuth ZRM. Figure 8-74: Azimuth ZRM, disconnect connector Loosen the 2x4 mm Allen screws. Figure 8-75: Azimuth ZRM, disconnect connector 9. Slide out the Azimuth ZRM. To insert a new Azimuth ZRM follow the instructions above in reverse order.

  • Page 174: To Replace The Inertial Sensor Module (Ism)

    Removal and replacement of ADU modules 8.6.10 To replace the Inertial Sensor Module (ISM) Locate the ISM, see Overview on page 8-11. To remove the ISM, do as follows: 8.6.11 To replace the RF Pack To remove the RF Pack do as follows: Tools needed: 1.
  • Page 175 Removal and replacement of ADU modules 8. Loosen the 4 screws holding the cable wrap in place (torque value: 2.5 Nm). Figure 8-77: Loosening the cable wrap 9. Loosen the four screws holding the Ka RF package. A few millimeters is enough, you do not need to remove them completely.

  • Page 176: To Replace The Buc

    Removal and replacement of ADU modules 13.TBC: Remove the 4 screws as shown in the following figure. Figure 8-79: Antenna ready for the Ka RF unit Assemble in reverse order. 8.6.12 To replace the BUC To remove the BUC, do as follows: Tools needed: 1.
  • Page 177 Removal and replacement of ADU modules 4. Gently pull out the BUC and slide it out of the case. Figure 8-81: Removal of the BUC 5. Insert the new BUC and assemble in reverse order. 99-145912-A Chapter 8: Service & maintenance 8-63...

  • Page 178: To Replace The Lnb

    Removal and replacement of ADU modules 8.6.13 To replace the LNB To remove the LNB, do as follows: Tools needed: 1. Follow instructions in To replace the RF Pack on page 8-60. 2. Remove the BCM. • 4 x 150 mm Allen key (located inside the service 3.

  • Page 179: To Replace The Rotary Joint

    Removal and replacement of ADU modules 8.6.14 To replace the rotary joint Figure 8-84: Rotary joint To remove the rotary joint do as follows: Tools needed: 1. Open the service hatch. • TX20 2. Switch off the power to the antenna on the service switch. •...
  • Page 180 Removal and replacement of ADU modules 1. Open the service hatch. Tools needed: 2. Switch off the power to the antenna on the service switch. • TX20 3. Loosen the 4 x M6 hexagonal head screws that connect the wire rope isolator to the antenna.

  • Page 181: To Update Vim2/Pcm Calibration Data

    To update VIM2/PCM calibration data To update VIM2/PCM calibration data After installing a new VIM2 (VSAT Interface Module) or PCM (Pedestal Control Module) you must update the calibration data. The ACU does not know which of the two modules (PCM or VIM) has been replaced.
  • Page 182 To update VIM2/PCM calibration data showing the status of both modules as Valid (Select boxes are greyed out). Figure 8-90: XIM data valid The XIM data are now updated and the SAILOR 100 GX is operational again. 8-68 Chapter 8: Service & maintenance...

  • Page 183: Inspection Of Mechanical Components

    Inspection of mechanical components Inspection of mechanical components 8.8.1 Inspection for critical wear This chapter contains guidelines on how to manually inspect the mechanical components of the ADU for critical wear. Note that this inspection requires a solid understanding of the ADU components and is best done by a certified service partner.
  • Page 184 Inspection of mechanical components The following figure shows a healthy wire-rope isolator and a critically worn-down isolator. Note the two broken wires on the second picture. They indicate that this wire-rope isolator must be replaced. NOT OK Figure 8-92: Inspection of a wire-rope isolator 1/2 Another sign of excessive wear is illustrated in the following figure.
  • Page 185 Inspection of mechanical components Note the deformed top bar and bottom bar. They indicate that this wire- rope isolator must be replaced. NOT OK Figure 8-93: Inspection of a wire-rope isolator 2/2 For instructions on how to replace a wire-rope isolator see To replace a wire-rope isolator on page 8-65.

  • Page 186: Troubleshooting

    8.9.1 Overview This section describes an initial check of the primary functions of the SAILOR 100 GX 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 ACU display showing the active events.
  • Page 187 Diagnostic report Below is an example of a system which has failed to power up. The SAILOR 100 GX will after ended POST go into safe mode, identified by the "ADU_IF: Error type not eligible for ADU auto recovery (14:20)".
  • Page 188 Troubleshooting The system log holds a minute by minute status readout from the system. The system log below holds three active (ON) events. 8..9.3.2 How to read system messages In the system messages you can match the ID and Description. 8-74 Chapter 8: Service &...
  • Page 189 Troubleshooting 99-145912-A Chapter 8: Service & maintenance 8-75...
  • Page 190 Troubleshooting 8.9.4 Troubleshooting Figure 8-94: Flow chart for troubleshooting 8-76 Chapter 8: Service & maintenance 99-145912-A...

  • Page 191: X-Elevation Bearing Test

    3. Go to DASHBOARD and monitor the field System status. If the field ends up showing Tracking, the SAILOR 100 GX can track the satellite and is most likely not the reason why the VSAT modem is not in RX lock.

  • Page 192: To Return Units For Repair

    To return units for repair 8.10 To return units for repair Should your Cobham SATCOM product fail, please contact your dealer or installer, or the nearest Cobham SATCOM partner. You will find the partner details on www.cobham.com/satcom where you also find the Cobham SATCOM Self Service Center web-portal, which may help you solve the problem.

  • Page 193: Appendix A Technical Specifications

    Appendix A Technical specifications This appendix has the following sections: • SAILOR 100 GX system components • Outline drawings SAILOR 100 GX system components A.1.1 General specifications Item Specification Frequency band Ka-Band (Inmarsat GX) 19.2 to 20.2 GHz 29.0 to 30.0 GHz Reflector size 103 cm (40.6 inch)

  • Page 194: Adu

    SAILOR 100 GX system components A.1.2 Item Specification antenna Antenna type, pedestal 3-axis (plus skew) stabilised tracking with integrated GPS Antenna type, reflector system Reflector/sub-reflector, ring focus Transmit Gain 47.5 dBi typ. @ 29.5 GHz (excluding radome) Receive Gain 44.0 dBi typ. @ 19.7 GHz (excluding radome) 20.1 dB/K typ.
  • Page 195 SAILOR 100 GX system components Item Specification Wind resistance Operational: 80 kt. Survival: 110 kt. Survival: 25 mm (1 inch) Solar radiation 1120 W/m to MIL-STD-810F 505.4 Compass safe distance 100 cm to EN 60945 Maintenance, scheduled None (T >10°C)

  • Page 196: Acu

    SAILOR 100 GX system components A.1.3 Item Specification Dimensions, rack mount 1 U, 19 inch 4.4 x 48 x 33 cm (1.75 x 19 x 13 inch) H x W x D Weight 4.5 kg (10 lbs) Ambient temperature Operational: -25°C to +55°C Storage: -40°C to +85°C...

  • Page 197: Gmu

    SAILOR 100 GX system components A.1.4 Item Specification Dimensions, rack mount 1 U, 19 inch 4.4 x 48 x 33 cm (1.75 x 19 x 13 inch) H x W x D Weight 4.5 kg (10 lbs) Ambient temperature Operational: -25°C to +55°C Storage: -40°C to +85°C...

  • Page 198: Adu

    Outline drawings Outline drawings A.2.1 Figure A-1: Outline drawing: ADU Appendix A: Technical specifications 99-145912-A...

  • Page 199: Acu

    Outline drawings A.2.2 Figure A-2: Outline drawing: ACU, 19 inch rack 99-145912-A Appendix A: Technical specifications...

  • Page 200: Gmu

    Outline drawings A.2.3 Figure A-3: OUtline drawing, GMU Appendix A: Technical specifications 99-145912-A...

  • Page 201: N-Connector Interface On The Adu

    Outline drawings A.2.4 N-connector interface on the ADU Figure A-4: N-Connector interface on the ADU 99-145912-A Appendix A: Technical specifications...
  • Page 202 Outline drawings A-10 Appendix A: Technical specifications 99-145912-A...

  • Page 203: Appendix B Ground And Rf Protection

    • Jumper cable for grounding Why is a ground connection required? You must grounding the SAILOR 100 GX system for at least two reasons: • Safety: Lightning protection of persons and equipment. • Protection: ESD (ElectroStatic Discharge) protection of equipment.

  • Page 204: Recommendations

    Recommendations Recommendations B.2.1 To ground the ACU To ground the ACU do as follows: 1. Ground the ACU to the ship/hull. For this purpose you may use a short ADU cable and a grounding kit. 2. Further, the ACU must be grounded at its grounding stud in order to ensure proper grounding if the short ADU cable is disconnected.
  • Page 205 Recommendations 2. Run the foil past the place where the short ADU cable is to be grounded and mount a grounding kit on top of the foil. For details on the jumper cable see Jumper cable for grounding on page B-14. Jumper cable Cable to ADU Figure B-1: Extending the ground plane...

  • Page 206: To Ground The Acu

    Alternative ground for steel hulls B.2.2 To ground the ADU To ground the ADU do as follows: 1. Ground the ADU to the ship/hull via one or more of its mounting bolts. 2. Make sure to remove painting, dirt, grease etc. at the mounting holes in order to make good electrical contact to the hull.

  • Page 207: To Ground The Acu

    Alternative ground for steel hulls 2. Further, ground the ACU at its grounding stud in order to ensure a proper grounding if the short ADU cable is disconnected. 3. Establish the ground connection either at the hull (recommended) or at a dedicated RF ground if available (alternative). However, bear in mind that the ADU ground Important connection must be made at the same electrical...
  • Page 208 Alternative ground for steel hulls Figure B-3: Grounding at a dedicated RF ground (alternative) Appendix B: Ground and RF protection 99-145912-A...

  • Page 209: To Ground The Adu

    Alternative ground for aluminum hulls Alternative ground for aluminum hulls The following guidelines assume a two-wire, isolated grounding arrangement; that is no part of the circuit, in particular the battery negative, is connected to any ground potential or equipment. B.4.1 To ground the ACU To ground the ACU do as follows: 1.
  • Page 210 Alternative ground for aluminum hulls Figure B-4: Alternative grounding for aluminium hulls Appendix B: Ground and RF protection 99-145912-A...

  • Page 211: Alternative Ground For Fibre Glass Hulls

    Alternative ground for fibre glass hulls Alternative ground for fibre glass hulls B.5.1 To ground the ACU To ground the ACU do as follows: 1. Preferably ground the ACU with the short ADU cable and a grounding kit (available from Thrane & Thrane A/S). 2.
  • Page 212 Alternative ground for fibre glass hulls Figure B-5: Alternative grounding for fibreglass hulls B-10 Appendix B: Ground and RF protection 99-145912-A...

  • Page 213: Separate Ground Cable

    Separate ground cable Separate ground cable B.6.1 To construct a ground cable When dealing with electrical installations in a marine environment, all wiring must be done with double insulated, tinned strands, high quality and if exposed also UV resistant cables. This shall also apply to the separate ground cable mentioned in the previous paragraphs.

  • Page 214: Ground Cable - Connection

    Separate ground cable B.6.2 Ground cable - connection To mount the ground cable do as follows: 1. Mount the ground cable close to and parallel to the shielded coax cable thus minimizing ground loop problems. If possible, route the coax cable and the ground cable in metal conduits bonded to the hull or within a mast (depending on the actual installation).

  • Page 215: Rf Interference

    RF interference Interference induced from nearby high-power RF transmitters might cause system failures and in extreme cases permanent damage to the SAILOR 100 GX equipment. If there are problems with interference from HF transmitters, do as follows: 1. Mount ferrite clamps on the coax cable in order to provide suppression of induced RF.

  • Page 216: Jumper Cable For Grounding

    Jumper cable for grounding Jumper cable for grounding Figure B-9: Jumper cable for grounding (specifications) B-14 Chapter B: Ground and RF protection 99-145912-A...

  • Page 217: Appendix C System Messages

    • CM (Continuous Monitoring) – automatically performed while the system is in operation. When the SAILOR 100 GX detects an event that requires your action, it issues an event message and the red Fail/Pass LED in the LED panel of the ACU is lit.

  • Page 218: List Of Adu Events

    List of ADU events List of ADU events Error code Unit Severity Description Explanation (ID) 0A001-0 Antenna ERROR Production data Production data is invalid. 0A002-0 Antenna ERROR XIM internal Antenna configuration data stored in the PCM module is invalid. 0A003-0 Antenna ERROR XIM external Antenna configuration data stored in the VIM/TIM module is invalid.
  • Page 219 List of ADU events Error code Unit Severity Description Explanation (ID) 0A018-0 Antenna ERROR ISM ABS device Cannot initialise the ISM Info: 0x00000000: Device not found (possible cabling problem) 0x000cbbaa: Device internal error (replace device) aa=status, bb=state, c=calibration data error. 0A019-0 Antenna ERROR PMM ABS device Cannot initialise the PMM.
  • Page 220 List of ADU events Error code Unit Severity Description Explanation (ID) 0A02B-0 Antenna ERROR ABS software The ABS software version in the antenna is too version old to match the hardware requirements. Upgrade the software. 0A02D-0 Antenna ERROR BUC reference The BUC reference switches do not work.
  • Page 221 List of ADU events Error code Unit Severity Description Explanation (ID) 0A043-0 Antenna WARNING LNB voltage low The voltage for the LNB is too low probably caused by a malfunctioning VIM/TIM or LNB. 0A044-0 Antenna WARNING LNB voltage high The voltage for the LNB is too high probably caused by a malfunctioning VIM/TIM.
  • Page 222 List of ADU events Error code Unit Severity Description Explanation (ID) 0A053-0 Antenna ERROR Communication error between PCM and ISM. communication Check SUB-D connectors and cables. 0A054-0 Antenna ERROR Communication error between PCM and PMM. communication Check SUB-D connectors and cables. 0A055-0 Antenna WARNING Azi DDM warning The azimuth motor controller has temporarily observed an unusual situation with regards to...
  • Page 223 List of ADU events Error code Unit Severity Description Explanation (ID) 0A05A-0 Antenna WARNING Xel cal. limits Cross-elevation axis calibration result check limits exceeded. Pointing performance may be degraded. Info: See 0A059-0. 0A05B-0 Antenna WARNING Ele cal. limits Elevation axis calibration result check limits exceeded.

  • Page 224: List Of Acu Events

    List of ACU events List of ACU events Error code Severity Description Explanation (ID) 08060-0 ADM WARNING Antenna modem ACU/Antenna communication error detected (framing and parity). If the situation is persistent, check if cable specifications comply (length and attenuation). 08063-0 ADM ERROR Antenna connection The ACU has lost connection with the antenna.
  • Page 225 List of ACU events Error code Severity Description Explanation (ID) 0806F-0 ADM WARNING ROSS synchronization The ACU has become out of sync with the ROSS device, most likely because the ACU has been replaced, or the ROSS satellite profile is new. A manual (forced) handoff sequence must be initiated from the ROSS, refer to the ROSS manual for the procedure.
  • Page 226 List of ACU events Error code Severity Description Explanation (ID) 0810B-0 ADM ERROR Antenna software Some error occurred during upload of software to version the antenna, which means that the antenna software version is not as expected. Either the software in the ACU, does not meet the minimum version required by the antenna, the software image in the ACU is corrupted or the upload procedure failed because of a communication...
  • Page 227 List of ACU events Error code Severity Description Explanation (ID) 08A01-0 ADM WARNING GX Core Module heater There is a problem with the Core Module heater. Check and replace if necessary. 08A02-0 ADM WARNING GX Core Module The Core Module temperature is out of range. It temperature may affect performance, and it will be shut down if the situation gets worse.
  • Page 228 List of ACU events C-12 Appendix C: System messages 99-145912-A...

  • Page 229: Appendix D Command Line Interface

    Appendix D Command line interface Introduction After you have done the initial configuration and connected the SAILOR VSAT system to your network, you can use Telnet to configure the SAILOR VSAT system. You can also setup VSAT modem parameters. H:\>telnet 192.168.0.1 UCLI:/$ config current_list UCLI:/$ config activate acu login: admin...

  • Page 230: Help

    Supported commands D.1.2 Help If you enter help directly at the prompt UCLI:/$ all available commands are listed. Additionally any command will take help as first argument and display detailed information of the specific command. D.1.3 Conventions The command description below uses the following special typography: Convention Description Information that is displayed on the screen.

  • Page 231: Config

    Supported commands D.2.1 config Command Description Shows the sub commands available, including a short config description. config pending_list Shows the number of pending changes. config current_list Shows the values for the current satellite profile, antenna and some tracking information. Discards all pending changes. config discard Use this command to save and activate the pending config activate...

  • Page 232: Exit

    Supported commands D.2.4 exit Command Description Exits the connection to the SAILOR VSAT system. exit Table D-5: UCLI command: exit D.2.5 help Command Description Shows a list of commands available, including a short help description. help satellite Shows the sub commands and description for the command satellite.

  • Page 233: Satellite

    Supported commands Command Description Shows the currently active VSAT modem model (selected in the modem model web interface). modem gps_fix Shows the current GPS position modem gps_lat Shows the latitude value of the current position. modem gps_lon Shows the longitude value of the current position. Table D-7: UCLI command: modem (Continued) D.2.7 satellite...
  • Page 234 Supported commands Command Description Shows or sets the current TX polarisation: satellite tx_pol • v (vertical) satellite tx_pol v • h (horizontal) • l (left) • r (right) Shows or sets the elevation referenced to earth satellite ele_cut_off where the SAILOR VSAT system must shut off for transmission.
  • Page 235 Supported commands Command Description Shows or sets the IF Rx frequency together with satellite rx_if_freq the LNB Lo frequency. • Ku band: satellite rx_if_freq IF frequency within 950 MHz – 2150 MHz. 1200.123 9.75 LNB Lo frequency within 9.6 GHz – 11.3 GHz. The SAILOR VSAT system supports any LNB Lo.

  • Page 236: Status

    Command Description Shows the sub commands available, including a short status description. Shows the current status of the SAILOR 100 GX. status system Shows the current values for all tracking parameters: status track_all • vessel heading • azimuth relative •...

  • Page 237: Track

    Shows or sets the receiver bandwidth or mode, the way track mode the SAILOR 100 GX tracks the satellite: • narrow (recommended, uses the built-in 300 kHz track mode dvb filter of the SAILOR 100 GX) • rssi (uses the RSSI signal from the VSAT modem) •...

  • Page 238: Zone

    Supported commands D.2.11 zone Command Description Shows the sub commands, unit and zone description for the command zone. Sets the azimuth angles of the blocking zone zone <id> azimuth <start for one zone. angle> <end angle> • Valid zones: 0 to 7 •...

  • Page 239: Appendix E Approvals

    This appendix lists the approvals for SAILOR 100 GX: • CE (R&TTE) CE (R&TTE) The SAILOR 100 GX is CE certified (R&TTE directive) as stated in the “Declaration of Conformity with R&TTE Directive”, enclosed in copy on the next page.
  • Page 240 CE (R&TTE) Appendix E: Approvals 99-145912-A...

  • Page 241: Glossary

    Glossary Glossary ADU Bus Slave Antenna Control Unit ACU Digital Module. A main processor board in the ACU. Antenna Module Bus Block Up Converter - The BUC can be thought of the “transmitter”, and its actions are effectively the direct opposite to the LNB. The BUC consists of the Up Converter and HPA. Conformité...
  • Page 242 Glossary FPGA Field Programmable Gate Array GNSS Global Navigation Satellite System, e.g. GPS. General Public License Global Positioning System. A system of satellites, computers, and receivers that is able to determine the latitude and longitude of a receiver on Earth by calculating the time difference for signals from different satellites to reach the receiver.
  • Page 243 Glossary Management Information Base Network IDentification NMEA National Marine Electronics Association (standard). A combined electrical and data specification for communication between marine electronic devices such as echo sounder, sonars, anemometer (wind speed and direction), gyrocompass, autopilot, GPS receivers and many other types of instruments. It has been defined by, and is controlled by, the U.S.-based National Marine Electronics Association.
  • Page 244 Glossary SNMP Simple Network Management Protocol. An Internet-standard protocol for managing devices on IP networks. It is used mostly in network management systems to monitor network-attached devices for conditions that warrant administrative attention. Secure Shell. A network protocol for secure data communication, remote shell services or command execution and other secure network services between two networked computers that it connects via a secure channel over an insecure network.

  • Page 245: Index

    Index Index antenna , 3-16 drainage access , B-4 grounding recommendations , 6-34 limit , 3-3 installation location acquisition , B-12 isolation from mounting base , 6-8 gyro-free , 3-8 mast design , 6-7 search pattern , 3-4 obstructions , 6-8 search pattern, inclined orbit , 3-21 opening...
  • Page 246 Index , 6-11 cable calibration configuration , 6-11 , 6-36 service copy , 6-36 cable loss export , 3-18 , 6-36 ADU cable import , 6-24 cable requirements LAN network , 4-4 , 6-16 NMEA site map , 6-1 cable size step-by-step , A-9 , 6-1...
  • Page 247 Index , 2-2 distance Features , 3-15 antenna to GPS receiver fiberglass hulls , 3-13 , B-9 antenna to radar grounding , 6-26 , 6-1 DNS setup fire wall , 3-16 drainage of antenna fix antenna , 2-5, 8-21 drawing lock , A-7 , 6-6, 6-7...
  • Page 248 Index , 8-2 helpdesk number log off , 8-2 , 6-34 changing in web interface administrator , 6-17, 6-24 host name login , 3-16 , 6-34 humidity in antenna guest logon , D-1 administrator, command line interface , 6-32 administrator, web interface impedance , 5-3 cable...
  • Page 249 Index network power cable , 6-24 , 5-1 LAN setup selection , 8-11 NMEA Power On Self Test , 4-4 , 2-6 cable requirements power supply , 4-3 , 6-34 connector protect access to settings , 4-3 , 3-25 provisioning key , 4-4 , 8-4 supported string...
  • Page 250 Index , 5-1 satellite start-up current , D-5 , 6-1 command line interface static IP , 6-26 satellite data static IP address , 8-9 calibration statistics , 6-28, 6-31 satellite profile sampling frequency , 6-21 , 6-27 activate send by e-mail , 6-28, 6-29 save statistics report...
  • Page 251 Index , 8-5 updating software upload , 6-36 configuration , D-1 user CLI user name , D-1 UCLI , 6-35 user permissions , 6-34 setup , 4-3, 4-6, 4-8 VMU connector VSAT modem , 8-10 supported types , C-1 warning messages , 8-3 warnings , 8-78...
  • Page 252 99-145912-A www.cobham.com/satcom...

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