Sailor900gx Ckit Im 98 141783 C

SAILOR 900 GX Conversion Kit
Hardware installation guide

SAILOR900GX-CKit-IM-98-141783.book Page i Wednesday, August 16, 2017 2:17 PM
SAILOR 900 GX Conversion Kit
Hardware installation guide
Document number: 98-141783-C

Release date: 16 August 2017
SAILOR900GX-CKit-IM-98-141783.book Page ii Wednesday, August 16, 2017 2:17 PM
Disclaimer
Any responsibility or liability for loss or damage in connection with the use of this product and the
accompanying documentation is disclaimed by Thrane & Thrane A/S. The information in this manual is
provided for information purposes only, is subject to change without notice and may contain errors or
inaccuracies. Manuals issued by Thrane & Thrane A/S are periodically revised and updated. Anyone
relying on this information should acquire the most current version e.g. from www.cobham.com/satcom,
Cobham SYNC Partner Portal, or from the distributor. Thrane & Thrane A/S is not responsible for the
content or accuracy of any translations or reproductions, in whole or in part, of this manual from any
other source. In the event of any discrepancies, the English version shall be the governing text.
Thrane & Thrane A/S is trading as Cobham SATCOM.
Address
Thrane & Thrane A/S, Lundtoftegaardsvej 93 D, DK-2800, Kgs. Lyngby, Denmark
Copyright
© 2017 Thrane & Thrane A/S. All rights reserved.
Record of Revisions
Rev. Description Release Date Initials
A Original document 16 September 2014 UFO
The following section has been edited: 1.3.

B The following figures have been edited: 1-25, 1-26, 1- 18 May 2016 UFO
28, 1-29
Updated with SAILOR 7016C ACU, new label and

C 16 August 2017 UFO
changed web interface pages.
ii 98-141783-C
SAILOR900GX-CKit-IM-98-141783.book Page iii Wednesday, August 16, 2017 2:17 PM
Table of contents
Chapter 1 Conversion to GX
1.1 To unpack ...............................................................................................................................1-1
1.1.1 What’s in the boxes ............................................................................................................1-1
1.1.2 Initial inspection ..................................................................................................................1-2
1.1.3 Tools needed .........................................................................................................................1-2
1.2 Prerequisites .........................................................................................................................1-3
1.3 To exchange the ACU ...................................................................................................1-3
1.4 To exchange the VSAT modem .............................................................................1-4
1.5 To connect the ADU, ACU and GMU ................................................................1-5
1.6 To modify the ADU .........................................................................................................1-6
1.6.1 New VSAT Interface Module (VIM3) ........................................................................1-7
1.6.2 New RF pack ..........................................................................................................................1-9
1.6.3 New Ka feed horn (black) .............................................................................................1-15
1.6.4 New labels for antenna .................................................................................................. 1-16
1.7 To connect the new ACU to the modem ................................................... 1-16
1.8 To update the calibration data in VIM3 .....................................................1-17
1.8.1 To access the web interface ....................................................................................... 1-17
1.8.2 To update the calibration data to GX .....................................................................1-18
98-141783-C iii
SAILOR900GX-CKit-IM-98-141783.book Page iv Wednesday, August 16, 2017 2:17 PM
Table of contents
iv 98-141783-C
SAILOR900GX-CKit-IM-98-141783.book Page 1 Wednesday, August 16, 2017 2:17 PM
1111
Chapter 1
Conversion to GX
Conversion to GX
1
This chapter has the following sections:

• To unpack
• Prerequisites
• To exchange the ACU
• To exchange the VSAT modem
• To modify the ADU
• To update the calibration data in VIM3
Note This guide describes the hardware installation when converting a SAILOR 900
VSAT Ku with the 407009B ADU and the 407016A ACU to a SAILOR 100 GX
system with the SAILOR 7016C ACU and the SAILOR 7023A GMU. Once you have
converted the hardware, refer to the SAILOR 100 GX installation manual for
setup and configuration.
1.1 To unpack
The following sections list the contents of the conversion kit, give information about initial
inspection and list the tools needed during the conversion process.
1.1.1 What’s in the boxes

Unpack and check that the following items are present:
• SAILOR7016C ACU (407016C-T19)
• Accessory kit
• SAILOR 100 GX Installation manual
• SAILOR 7023A GMU (407023A-T19)
• Accessory kit for SAILOR 7023 GMU including
• Wiecon 3.5 mm spacing, 4 pol connector for cable
• RJ45 patch cable (1 pce)
• Power cable 230 VAC
• RS-232/RS-422 cable (2 pcs)
• RF pack consisting of
• Unit label 46x22 mm (for antenna)
• VIM3
• Ka RF Unit (BUC/LNB)
• Ka feed horn
• Double open-end wrench 24/30 mm
• RJ45 patch cable
• SAILOR 900 GX Conversion Kit, Hardware installation guide (this manual)
98-141783-C 1-1
To unpack
1.1.2 Initial inspection

Inspect the shipping carton 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 is present when opening the cartons. Save all box packing material for future
use.
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.
After unpacking the received items, inspect them thoroughly for hidden damage and loose
components or fittings. If the contents are incomplete, if there is mechanical damage or
defect, or if the system does not work properly, notify your dealer.
1.1.3 Tools needed

The following tools are needed for the conversion:
• Torx TX25 to open the locks of the service hatch
• Unbraco key (4 mm), mounted on a tool holder inside the ADU radome.
• 8 mm open-end spanner (SMA connector)
• 18 mm open-end spanner (N connector)
• Flat-head screw driver
• Double open-end wrench 24/30 mm for exchanging the feed horn (part of the
conversion kit)
• PC with Internet browser
Note All screws are 4 mm Allen screws. Loctite is not needed.
1-2 Chapter 1: Conversion to GX 98-141783-C

1111
Prerequisites
1.2 Prerequisites
Conversion to GX
CAUTION! You must update the existing ACU to the latest software
version available (minimum 1.55) before you convert the system. Otherwise
the system may become inoperable.
You can export the current configuration and use it as a reference after the conversion.
Important Note the blocking zones of your installation in the table below. The new ACU
has no blocking zones to start with, you must enter them manually.
Active Azimuth (°) Elevation (°) No TX
Table 1-1: Blocking zones of the installation
1.3 To exchange the ACU

To update and exchange the ACU, do as follows:
1. Switch on the SAILOR 7016A Ku ACU.

2. Make a software update to the latest available software. For details how to access the
web interface see To access the web interface on page 1-17.
3. Switch off the SAILOR 7016A Ku ACU.
4. Remove all cables from the SAILOR 7016A Ku ACU.
5. Remove the screws at each side and take the SAILOR 7016A Ku ACU out of the 19”
rack.
6. Slide the SAILOR 7016C ACU into the free 1U space in the 19” rack.
7. Mount the screws in each side through the holes in the front and fasten the screws to
the rack. Make sure that the unit is mounted securely according to the requirements for
your 19” rack.
For information about grounding the ACU see the SAILOR 100 GX Installation manual.
98-141783-C Chapter 1: Conversion to GX 1-3

To exchange the VSAT modem
1.4 To exchange the VSAT modem

The following sections describe how to exchange the VSAT modem.
To exchange the VSAT modem, do as follows:
1. Switch off the VSAT modem.

2. Remove all cables from the VSAT modem.
3. Remove the screws at each side and take the VSAT modem out of the rack.
4. Slide the SAILOR 7023A GMU into the 1U space in a 19” rack., preferably directly
below or above the ACU.
5. Mount the screws in each side through the holes in the front and fasten the screws to
the rack. Make sure that the unit is mounted securely according to the requirements for
your 19” rack.
6. Make sure that the grounding requirements are met. See the SAILOR 100 GX Installation
manual for details about grounding.

1111
To connect the ADU, ACU and GMU
1.5 To connect the ADU, ACU and GMU
Conversion to GX
The following figure shows how to connect the ADU, ACU and GMU.
$&SRZHU
*08

$&SRZHU
$&8
Figure 1-1: Connection between ADU, ACU and GMU
Important Pay attention to where the RX and TX cables go in the new ACU (SAILOR
7016C): TX In left, RX Out right.
Pay attention to where the RS422 and RX 232 cables go in the new ACU
(SAILOR 7016C): RS-232 on top, RS-422 below.
1. Connect the antenna cable (1) to Antenna at the ACU and the antenna.
2. Connect Rx Out at the ACU to Rx In at the GMU with the supplied cable (2) (75 Ohm
coax, F-F, 1 m).
3. Connect Tx In at the ACU to Tx Out at the GMU with the supplied cable (3) (75 Ohm
coax, F-F, 1 m).
4. Connect RS-232 on the ACU to RS-232 (right) at the GMU with cable (4).
5. Connect RS-422 on the ACU to RS-422 at the GMU with cable (5).
6. Connect a PC at the LAN3 interface (Service port) of the ACU for access to the web
interface for configuration1 with cable (6).
7. Connect LAN1 at the ACU to the upper left LAN connector at the GMU with the cable
(7).
1. This port is used in configurations with an NSD box.

To modify the ADU
1.6 To modify the ADU

The GX conversion procedure of the ADU consists of the following steps:
• New VSAT Interface Module (VIM3)
• New RF pack
• New Ka feed horn (black)
• New labels for antenna
To power off and open the service hatch
1. Switch off the power to the ACU.

2. Use a Torx TX25 screw driver to loosen the two screws (A) locking the latches of the
service hatch.
3. Pull open the two latches and let the lid fall open.
(A) (A)
Figure 1-2: To open the service hatch
You may remove the hatch for better mobility when servicing the antenna.
When inserting the hatch again lock the two latches of the service hatch by fastening the
two screws in the latches with a Torx TX25 screw driver to protect the ADU against
unauthorised access.

1111
To modify the ADU
1.6.1 New VSAT Interface Module (VIM3)
Conversion to GX
To replace the VIM1 with the VIM3, do as follows:
1. Rotate the antenna pedestal so that the arm of the GPS/GNSS module faces the service
hatch.
2. Rotate the antenna dish to top position.
3. Press in and turn the elevation locking pin to top position.
Elevation locking pin
Figure 1-3: Elevation locking pin
4. Disconnect the 2 SMA connectors at the top of the VIM1.
B (1 Nm)
A (1 Nm)
B (1 Nm)
A (1 Nm)
Figure 1-4: Replacement of the VIM1

To modify the ADU
5. Disconnect the N-connector at the top (A) and the one at the bottom of the VIM1 (B),
the SUB-D-connector (C), then the SMA connector (D) at the bottom of the VIM1.
A (2 Nm)
D (1 Nm)
B (2 Nm)
C (manual)
Figure 1-5: Replacement of the VIM1 (Continued)
6. Loosen the 4 screws to remove the VIM1.
(2.5 Nm)
Figure 1-6: Replacing the VIM1 — remove 4 Allen screws
7. Insert the new VIM3 module, follow the instructions above in reverse order. Use the
cable wrench where appropriate.
8. Connect the cable X POL to B and CO POL to A.
Important After installing the VIM3 you must update the calibration data. See To
update the calibration data to GX on page 1-18.

1111
To modify the ADU
Conversion to GX
Figure 1-7: VIM3 module
1.6.2 New RF pack

To insert the new RF pack, do as follows:
1. Disconnect the Polarization unit at LNB 1 (A) and LNB 2 (B), BUC (C), and PMM (D).
(B)
(A)
(C)
(D)
Figure 1-8: RF Pack, disconnect cables

To modify the ADU
2. To remove the cable wrap from the Polarization unit loosen the 4 screws holding the
Polarization unit. Use the Allen key (4 mm), (inside the radome).
Figure 1-9: Removal of the cable wrap
3. Lower the cable wrap carefully and let it rest freely.
Figure 1-10: Cable wrap, loose

1111
To modify the ADU
4. Turn the Polarization unit (A) clockwise until all 4 screws are visible.
Conversion to GX
(A)
(B)
Figure 1-11: Polarization unit, access to 4 screws
5. Loosen the 4 screws. The screws stay in the antenna, do not remove them at this point.
6. Turn the Polarization unit counterclockwise as shown below and pull it carefully towards
you until a mechanical stop.
Important The Polarization unit weighs 11 kg. Remove it carefully out of the
radome.
Figure 1-12: Ku RF unit
7. Take out the Ku RF unit.

To modify the ADU
8. Move the 4 screws to the outer position as shown in the following figure.
Figure 1-13: Antenna ready for the Ka RF unit
9. Put the Ka RF unit in place. You must align the notch on the outer circumference to the
arrow as shown in the following figure.
Figure 1-14: Ka RF unit, alignment of notch to arrow
10.Fasten the 4 screws (torque value: 4.5 Nm).

1111
To modify the ADU
11.Fit the cable wrap and turn it until it locks, i.e. insert the orientation pin of the Ka RF unit
into the hole in the cable wrap.
Conversion to GX
Figure 1-15: Fitting of the cable wrap with orientation pin on the Ka RF unit
12.Fasten the 4 screws holding the cable wrap in place (torque value: 2.5 Nm).
Figure 1-16: Fastening the cable wrap

To modify the ADU
13.Connect the cable with SMA connector marked CO POL to the LNB (A) and the cable
with SMA connector marked X POL to the blind terminator (B).
(B)
(A)
Figure 1-17: Cable connection for CO POL and blind terminator
14.Connect the N connector from the cable wrap to the BCM (BUC Control Module) (A),
see figure below.
15.Connect the Sub-D connector to S-Bus IN (B), see figure below.
(B)
(A)
Figure 1-18: Cable connection from the cable wrap
16.Turn the elevation locking pin to unlock the antenna dish.

1111
To modify the ADU
1.6.3 New Ka feed horn (black)
Conversion to GX
To exchange the Ku feed horn (silver colour) with a Ka feed horn (black) do as follows:
1. Turn and tip the antenna so the feed horn faces you.
2. With the wrench remove carefully the Ku feed horn.
Figure 1-19: Removal of the Ku feed horn (silver colour)
You can see that there are two threads in the reflector: the one closest was the thread
for the Ku feed horn (silver colour), (A), the one further into the reflector is the thread for
the new Ka feed horn (black), (B).
(A)
(B)
Figure 1-20: Threads for Ku (A) and Ka (B) feed horn
3. Insert the Ka feed horn (black), first guide it manually into the opening until it gets hold
of the thread, turn it carefully all the way in, then fasten it with the wrench.
Figure 1-21: Insertion and fastening of Ka feed horn (black)

To connect the new ACU to the modem
1.6.4 New labels for antenna

The antenna must be equipped with new unit labels to identify it being an antenna
converted to Ka, i.e. a GX antenna. The new unit label includes the new serial number.
1. Place the new unit labels next to the existing unit labels.
Figure 1-22: New ADU unit label
2. Close the service hatch and lock the two latches by fastening the two screws in the
latches with a Torx TX25 screw driver.
1.7 To connect the new ACU to the modem

When you connect the new ACU (SAILOR 7016C) to the modem note that the RX Out and
TX In connectors have switched sides.
Important Pay attention to where the RX and TX cables go in the new ACU (SAILOR
7016C): TX In left, RX Out right.
Pay attention to where the RS-422 and RX-232 cables go in the new ACU
(SAILOR 7016C): RS-232 on top, RS-422 below.
RS-232
RS-422 TX In RX Out
Figure 1-23: Location of RX and TX connectors on ACU with AC power

1111
To update the calibration data in VIM3
1.8 To update the calibration data in VIM3
Conversion to GX
Before you can set up and configure the GX system you must update the calibration data in
the new VIM3. Instructions for all other setup and configuration tasks are described in the
SAILOR 100 GX installation manual.
1.8.1 To access the web interface

Use the built-in web interface to access the screen where you can update the calibration
data. Use a standard Internet browser.
To connect to the web interface of the ACU do as follows:
1. Power up the system, i.e. switch on the ACU and the GMU. Wait until the LEDs on the
front plate of the ACU 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.
2. Connect a PC to LAN interface 3 (Service port, standard Ethernet) of the ACU or to the
front LAN connector of the ACU if LAN3 is connected via the pass-through LAN
connector.
Figure 1-24: LAN 3 connector used for configuring the SAILOR 900 GX Conversion Kit
If you want to use another LAN port to access the web interface you must configure it
according to your network requirements. See the SAILOR 100 GX installation manual for
more information.
3. Open your Internet browser and enter the IP address of the ACU. The default IP address
is http://192.168.0.1.
4. When the logon screen is displayed you have verified that the connection to the
converted system can be established. The web interface is ready for use. You can
continue to configure the system.
5. If needed, type in the user name admin and the password 1234 to access the
Dashboard.
Figure 1-25: Logon screen (if enabled)
The web interface shows the DASHBOARD page.

Figure 1-26: Dashboard
1.8.2 To update the calibration data to GX

After installing a new VIM3 the calibration data must be updated.
1. Click SERVICE > Antenna data. A screen similar to the one in the figure below will
appear:
ADU serial Calibration data

number have not yet been
copied to the
VIM2 module.
Figure 1-27: Updating the calibration data to GX (example)
At Backup Unit the figure shows Upgrade, because the VIM module was removed and
the VIM3 module added.

1111
Important Make sure that you have finished mounting the VIM3 module, the RF unit
Conversion to GX
and the feed horn before you proceed. If not, this operation renders the
system non-operable and you must consult your service center.
2. Click Upgrade, then a warning appears.
Figure 1-28: Update of calibration data, warning
3. Click OK to continue, the calibration data is copied into the new VIM module.
Figure 1-29: Antenna data not ready
4. Do not click Refresh. The system reboots automatically. Wait until the system has
restarted and the DASHBOARD is displayed.
5. Click SERVICE > Antenna data. A screen similar to the one in the following figure is
displayed. The buttons Select and Upgrade are greyed out.
In the section LNB ID LNB specific values are displayed. They are also contained in the
diagnostics report.
Do not change these values. (The values for LNB must only be changed in case
another LNB is mounted in the antenna).
Do not click Apply.

ADU serial
number
Figure 1-30: Antenna data valid
To continue with setup and configuration see the SAILOR 100 GX Installation manual.

98-141783-C
www.cobham.com/satcom

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SAILOR 900 GX Conversion Kit

Hardware installation guide

SAILOR 900 GX Conversion Kit

Hardware installation guide

Document number: 98-141783-C

Rev. Description Release Date Initials

A Original document 16 September 2014 UFO

The following section has been edited: 1.3.

Updated with SAILOR 7016C ACU, new label and

This chapter has the following sections:

1.1.1 What’s in the boxes

1.1.2 Initial inspection

WARNING! To avoid electric shock, do not apply power to the system if

1.1.3 Tools needed

Note All screws are 4 mm Allen screws. Loctite is not needed.

1-2 Chapter 1: Conversion to GX 98-141783-C

Active Azimuth (°) Elevation (°) No TX

Table 1-1: Blocking zones of the installation

1.3 To exchange the ACU

1. Switch on the SAILOR 7016A Ku ACU.

98-141783-C Chapter 1: Conversion to GX 1-3

To exchange the VSAT modem

1.4 To exchange the VSAT modem

1. Switch off the VSAT modem.

1-4 Chapter 1: Conversion to GX 98-141783-C

1.5 To connect the ADU, ACU and GMU

Figure 1-1: Connection between ADU, ACU and GMU

1. This port is used in configurations with an NSD box.

98-141783-C Chapter 1: Conversion to GX 1-5

To modify the ADU

1.6 To modify the ADU

To power off and open the service hatch

1. Switch off the power to the ACU.

Figure 1-2: To open the service hatch

1-6 Chapter 1: Conversion to GX 98-141783-C

1.6.1 New VSAT Interface Module (VIM3)

Elevation locking pin

Figure 1-3: Elevation locking pin

4. Disconnect the 2 SMA connectors at the top of the VIM1.

Figure 1-4: Replacement of the VIM1

98-141783-C Chapter 1: Conversion to GX 1-7

To modify the ADU

Figure 1-5: Replacement of the VIM1 (Continued)

6. Loosen the 4 screws to remove the VIM1.

Figure 1-6: Replacing the VIM1 — remove 4 Allen screws

1-8 Chapter 1: Conversion to GX 98-141783-C

1.6.2 New RF pack

Figure 1-8: RF Pack, disconnect cables

98-141783-C Chapter 1: Conversion to GX 1-9

To modify the ADU

Figure 1-9: Removal of the cable wrap

3. Lower the cable wrap carefully and let it rest freely.

Figure 1-10: Cable wrap, loose

1-10 Chapter 1: Conversion to GX 98-141783-C

Figure 1-11: Polarization unit, access to 4 screws

Figure 1-12: Ku RF unit

7. Take out the Ku RF unit.

98-141783-C Chapter 1: Conversion to GX 1-11

To modify the ADU

Figure 1-13: Antenna ready for the Ka RF unit

Figure 1-14: Ka RF unit, alignment of notch to arrow

10.Fasten the 4 screws (torque value: 4.5 Nm).

1-12 Chapter 1: Conversion to GX 98-141783-C