COBHAM EXPLORER 8100 Ku Manual

EXPLORER 8100
Ku Conversion Kit
Hardware installation guide

98-155944-A i
Document number: 98-155944-A
Release date: 5 April 2017
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.
Copyright
© 2017 Thrane & Thrane A/S. All rights reserved.
Manufacturer address
Thrane & Thrane A/S, Lundtoftegaardsvej 93 D, DK-2800, Kgs. Lyngby, Denmark
Record of Revisions
Related documentation
Rev. Description Release Date Initials
A Original document 5 April 2017 CC
Document Part number
EXPLORER 8000 series, User & installation manual 98-145510
EXPLORER 8100 eTRIA Conversion Kit, Hardware installation guide 98-155435

98-155944-A ii
Table of contents
Chapter 1 Conversion to Ku-band
1.1 To unpack ................................................................................................................................... 1
1.1.1 What’s in the box .................................................................................................................... 1
1.1.2 Initial inspection ...................................................................................................................... 1
1.2 Prerequisites ............................................................................................................................. 2
1.2.1 Software version ...................................................................................................................... 2
1.2.2 Tools needed ............................................................................................................................. 2
1.3 To modify the Antenna ................................................................................................... 3
1.3.1 To prepare the Ka (eTRIA) antenna ............................................................................... 3
1.3.2 To remove the eTRIA ............................................................................................................ 5
1.3.3 To connect and arrange the cables ................................................................................ 6
1.3.4 To install the BUC ................................................................................................................... 9
1.3.5 To install the Ku RF assembly ..........................................................................................11
1.3.6 Final assembly .........................................................................................................................15
1.4 To update the configuration to Ku .......................................................................15
1.4.1 Configure the system to use the Ku feed ..................................................................15
1.4.2 Create and activate a satellite profile ..........................................................................16

98-155944-A 1
Chapter 1
Conversion to Ku-band
Conversion to Ku-band 1
This guide describes the hardware installation when converting an EXPLORER 8100 Ka
(eTRIA) antenna (408147B) to an EXPLORER 8100 Ku antenna, and the minimum initial
configuration necessary.
This chapter has the following sections:
•To unpack
•Prerequisites
•To modify the Antenna
•To update the configuration to Ku
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 box
Unpack the Ku Conversion kit and check that the following items are present:
•KuRFassembly
•8WBUC
• Front and rear brackets for 8 W BUC
•Waveguide,FlexibleWR-75,60cm
• Cable harness for connections between antenna pedestal and RF assembly
• Cable for BUC connection
• Screws and washers
• Cable ties and strips
• Splicing tape
• Hardware installation guide for EXPLORER 8100 Ku Conversion Kit (this manual)
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.
Note
Once you have converted the hardware, refer to the EXPLORER 8000 User and
installation manual (98-145510) for setup and configuration.

Prerequisites
2 Chapter 1: Conversion to Ku-band 98-155944-A
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.
1.2 Prerequisites
1.2.1 Software version
Before conversion, update the ACU software to minimum version 1.58.
1.2.2 Tools needed
The following tools are needed to convert an EXPLORER 8100 Ka (eTRIA) antenna to an
EXPLORER 8100 Ku antenna:
•Allen(hex)keyset
• Torx screwdriver set
•Adjustablewrench
• Cutting pliers (for cutting cable strips)
• Scalpel (for removing tape from the SMA connector at the eTRIA)

To modify the Antenna
98-155944-A Chapter 1: Conversion to Ku-band 3
Conversion to Ku-band
1.3 To modify the Antenna
The Ku conversion procedure of the antenna consists of the following operations:
•To prepare the Ka (eTRIA) antenna
•To remove the eTRIA
•To connect and arrange the cables
•To install the BUC
•To install the Ku RF assembly
•Final assembly
1.3.1 To prepare the Ka (eTRIA) antenna
Before you begin the conversion, the antenna must be open so you can access all the
relevant parts. You can unfold the antenna automatically or manually.
Unfold automatically
If you have a connected and powered system, you can deploy the antenna using the ACU
keypad or the web interface. Note that you must stop the antenna or disconnect power as
soon as the antenna is deployed, before the antenna starts to scan for a satellite. When you
have stopped the antenna, disconnect the antenna from the ACU.
Unfold manually
If your antenna is not connected, unfold the antenna manually with the hand crank as
follows:
Step 1 and 2 are only for antennas with the stow
lock mechanism (marked with this warning on the
elevation adjustment cover).
If you do not have this antenna version, go directly to
step 3.
1. In both sides of the antenna, use a hex L key to remove the screws for the circular
covers.
CAUTION! There are two stow versions of the antenna. One with a stow
lock mechanism and one with a stow brake. For the stow lock version it is
important to release the stow lock before adjusting the elevation.
Figure 1: Covers for manual elevation adjustment and stow lock release

To modify the Antenna
4 Chapter 1: Conversion to Ku-band 98-155944-A
2. Insert the hex L key at the top of the L-shaped hole, tip it downwards and follow the
direction of the hole to the left to release the lock.
3. Go back to the other side of the antenna and use the Hand crank to adjust the elevation
(turn clockwise to unfold the antenna).
4. Continue to adjust the elevation until you can access all parts mounted on the Feed arm.
5. Leave the hex L key in the stow lock release mechanism until you have finished
conversion and stowed the antenna.
Important
Leave the hex L key in the Released position while adjusting the
elevation.
Figure 2: Stow lock release
Note
If you have the stow brake version of the antenna you must first remove the
small cover. You can do this with the Hand crank.
Figure 3: Manual elevation adjustment
Figure 4: Ka-antenna ready for conversion

To modify the Antenna
98-155944-A Chapter 1: Conversion to Ku-band 5
Conversion to Ku-band
1.3.2 To remove the eTRIA
1. Carefully cut the tape protecting the connector and adapter (if present) at the eTRIA
and remove the tape.
2. Cut the strip holding the cable on the eTRIA.
3. Unplug the connector at the eTRIA.
4. Unscrew the four 6 mm hex screws on the eTRIA and carefully pull the eTRIA off and
away from the steering pins.
5. Carefully set the eTRIA aside.
Figure 5: Remove cable strip and tape at SMA connector for eTRIA
Note
Leave the other end of the cable connected to the antenna - it is going to be
reused for the Ku LNB later. Also leave the GNSS cable connected at both ends.
Figure 6: Remove screws for eTRIA
Cut cable strip
Remove tape
Steering pin
6 mm hex screw
6 mm hex screw
Steering pin
6 mm hex screw
6 mm hex screw

To modify the Antenna
6 Chapter 1: Conversion to Ku-band 98-155944-A
1.3.3 To connect and arrange the cables
For ease of access to cables and connectors, start by removing the reflector. Do as follows:
1. Unscrew the screws for the reflector while supporting the reflector.
2. Carefully set the reflector aside.
3. Remove the dust caps on the N-connector and GTC C4 connector behind the reflector.
4. Arrange the Tx cable for the Ku BUC under the Feed arm and mount cable strips loosely
to allow for final adjustment of the cable.
Figure 7: Take off reflector
Figure 8: Remove dust caps from connectors
Figure 9: Attach TX cable (view from under the Feed arm)
Dust caps
Cable strips
Tx cable

To modify the Antenna
98-155944-A Chapter 1: Conversion to Ku-band 7
Conversion to Ku-band
5. Fit the Tx cable behind the reflector and connect the angled connector of the cable to
the N-connector on the antenna. See Figure 10.
6. Take the cable harness and connect the GTC C4 connector behind the reflector.
7. Arrange the 3 cables in the cable harness together with the Tx cable and the 2 remaining
cables from the eTRIA installation and fit them all in the protective sleeve (6 cables in
total). The previous eTRIA cable will be reused as the Rx cable for the LNB and the GNSS
cable is reused as is.
8. Cut some of the cable strips that hold the existing cables on the Feed arm. Leave some
of them to hold the cables in place until the new cables are arranged.
Figure 10: Connect and arrange cables
Figure 11: Fit cables in protective sleeve
Figure 12: Cut cable strips
GTC C4
connector
N-connector
Protective
sleeve
Cable strips

To modify the Antenna
8 Chapter 1: Conversion to Ku-band 98-155944-A
9. Loosely attach the cables including the protective sleeve to the Feed arm with cable
strips. Allow space for a final adjustment of the cables.
10.Arrange the cables and work your way along the Feed arm while cutting the remaining
cable strips and placing new strips loosely around all the cables. Do not tighten the strips
until you have made the final adjustment of the cables.
Figure 13: Attach cables and protective sleeve
Figure 14: Arrange cables and place strips
Cable strip
Cable strip

To modify the Antenna
98-155944-A Chapter 1: Conversion to Ku-band 9
Conversion to Ku-band
1.3.4 To install the BUC
1. Mount the BUC brackets loosely with the included screws (2 screws each, if you are
using the brackets for the 8 W BUC). Place the bracket with the Waveguide interface
(square hole) closest to the free end of the Feed arm.
2. Mount the BUC so that the screw is facing the antenna pedestal. Attach the BUC to the
BUC bracket with the screw and 2 washers (one large Ø26x5 mm and one standard M4
washer). Tighten to torque 2.5 Nm.
3. Mount two of the screws on the waveguide side for temporary support of the BUC.
4. Remove the dust cap on the connector on the side of the BUC and connect the Tx cable
to the BUC. Tighten to torque 2.5 Nm.
Figure 15: Mount BUC brackets
Figure 16: Mount the BUC
Figure 17: BUC connection

To modify the Antenna
10 Chapter 1: Conversion to Ku-band 98-155944-A
5. While supporting the BUC, remove the supporting screws at the front of the BUC and fit
the two gaskets between bracket/BUC and Waveguide/bracket.
6. Mount the 4 screws and tighten them to torque 2.5 Nm.
7. Tighten the 4 screws for the BUC brackets to torque 10 Nm.
Figure 18: Waveguide, gaskets
Figure 19: Waveguide, mount screws
Figure 20: Tighten screws for BUC brackets

To modify the Antenna
98-155944-A Chapter 1: Conversion to Ku-band 11
Conversion to Ku-band
1.3.5 To install the Ku RF assembly
1. Carefully place the Ku RF assembly over the 2 steering pins (with the LNB pointing away
from the antenna pedestal) and mount the 4 screws (2 Hex screws and 2 Torx screws).
2. Connect the 4 cables for the RF assembly, 2 GTC C2 connectors at the Polarization unit
(coded for correct placement), one GTC C1 connector at the OMT and one SMA
connector at the LNB.
Figure 21: Mount RF assembly, close-up
Figure 22: Mount RF assembly
Figure 23: Mount cables for RF assembly
Hex screw
Torx screw
Steering pin

To modify the Antenna
12 Chapter 1: Conversion to Ku-band 98-155944-A
3. Adjust the SMA connector so that the cable exits to the right (after tightening) when the
OMT and LNB are in upright position. Tighten the connector to torque 1.7 Nm.
4. Protect the connection with splicing tape.
5. Attach the 2 cables for OMT and LNB to each other with a cable strip at the LNB
connector.
Figure 24: SMA connector on LNB
Figure 25: Seal connector at LNB
Figure 26: Cable strip at LNB

To modify the Antenna
98-155944-A Chapter 1: Conversion to Ku-band 13
Conversion to Ku-band
6. Continue to place strips at regular distances to hold the 2 cables together up to the Feed
arm.
7. Turn the OMT as far as possible in both directions in order to make sure the cable length
is sufficient.
8. Attach the 2 cables for the Polarization unit with the 3 dedicated screw-mount ties. Use
the screws already mounted on the Polarization unit to attach the cables in the three
positions shown (two along the side and one at the bottom of the Polarization
unit.Tighten the 3 screws to torque 2.5 Nm.
Figure 27: Cable strips on LNB and OMT cables
Figure 28: Attach cables to the Polarization unit
Screw-mount ties

To modify the Antenna
14 Chapter 1: Conversion to Ku-band 98-155944-A
9. Tighten all the strips along the Feed arm, starting at the Polarization unit, while adjusting
and arranging the cables along the way.
10.Arrange any excess cable length behind the reflector.
11.Cut off excess material from all the cable strips.
12.Connect the free end of the Waveguide to the OMT. Make sure the gasket is in place.
13. Mount the four Torx screws and tighten them to torque 2.5 Nm.
Figure 29: Cable strip on Feed arm
Figure 30: Connect Waveguide to OMT
Figure 31: Fasten Waveguide on OMT
Gasket

To update the configuration to Ku
98-155944-A Chapter 1: Conversion to Ku-band 15
Conversion to Ku-band
1.3.6 Final assembly
1. Mount the reflector again with the four screws on the back of the antenna. Tighten the
screws to torque 12 Nm.
2. Use the Hand crank to manually stow the antenna.
3. When the antenna is completely stowed (rubber bumpers lightly compressed), remove
the Hex L key you inserted before opening the antenna. (See To prepare the Ka (eTRIA)
antenna on page 1-3).
4. Remount the covers on the sides of the antenna and tighten them to torque 6 Nm.
5. The antenna is now converted to a Ku antenna, but you must do some initial
configuration before you can use the antenna. See the next section.
1.4 To update the configuration to Ku
Before you can use the antenna in the Ku system, you must make the following initial
configuration steps:
•Configure the system to use the Ku feed
•Create and activate a satellite profile
1.4.1 Configure the system to use the Ku feed
You must send a command to the ACU to let the system know that it now uses the Ku feed
instead of the eTRIA. Note that you must also enter the pol axis zero value, which is found
on the type label on the Polarization unit (called “Cal. value” on the type label).
Do as follows:
1. Power up the ACU and connect your computer to one of the LAN interfaces of the ACU
as described in the EXPLORER 8000 series User & installation manual.
CAUTION! If your antenna has the stow lock mechanism: After
stowing, never try to open the antenna manually again without first
inserting the Hex L key!
Note
Instructions for all setup and configuration tasks are described in the
EXPLORER 8100 installation manual.
Figure 32: Cal. value on type label for EXPLORER 8100 Ku Conversion Kit

To update the configuration to Ku
16 Chapter 1: Conversion to Ku-band 98-155944-A
2. Start a telnet session as described in the appendix “Command line interface” in the User
& installation manual.
3. Log in (default user name: admin, default password: 1234).
4. Enter the command: antenna_data type Ku <pol_zero> (where
<pol_zero> is the calibration value (“Cal. value”) found on the label on the
Polarization unit. See Figure 32 above).
Example: If the calibration value is 123456, type:
antenna_data type Ku 123456
The system restarts.
5. Check that the system starts up normally and not in Safe mode.
The display of the ACU shows if the system is in Safe mode.
6. Start a telnet session again and enter the command: calib aenc p.
This command starts calibration of the absolute encoder.
7. When the calibration is completed the antenna restarts. Wait until the Power LED and
the Fail/Pass LED on the ACU light steady green and the display shows “Not ready: Not
deployed”.
1.4.2 Create and activate a satellite profile
To create and activate your satellite profile with the web interface, do as follows:
1. Connect your computer to LAN 1 on the ACU, start your browser and enter the IP
address for the web interface (default http:\\192.168.0.1).
2. Select SETTINGS > Modem profiles and click New entry.
3. Type in a modem profile name of your own choice.
4. Select the modem you are going to use and fill in the requested information on that
modem. See the EXPLORER 8000 Series User & installation manual for details.
5. Click Apply.
You have now created your modem profile. Next step is to use it for a satellite profile.
6. Select SETTINGS > Satellite profiles and click New entry.
7. Type in a satellite profile name of your choice.
8. Select the modem profile you created above and fill in the parameters for the satellite
profile.
9. Click Apply.
You have now created your satellite profile. Next step is to activate it for use in the Ku
system.
10.In the Satellite profiles page, click Activate next to the new satellite profile.
After reboot the antenna will use the activated satellite profile.
Note
Existing modem profiles and satellite profiles for Ka-Band remain in the list, but
you cannot activate them. You can delete them if you want.