COBHAM SAILOR 1000 XTR Ka 4.5W ADU User manual

SAILOR XTR Ka
Installation manual

98-175666-A i
SAILOR XTR Ka
Quick guide
Installation wizard
This quick guide is for experienced service personnel who have installed the SAILOR XTR Ka system
before. It lists the minimum configuration tasks you have to make before the system can be used on-air
on a satellite.
1. Connect a PC to the front LAN connector of the Below Deck Unit (BDU).
2. Open an Internet Browser and type the default IP address of the SAILOR XTR Ka: https://192.168.0.1.
3. Bypass the admin password by pressing the left arrow key on the BDU for 5 seconds.
4. After opening the web interface for the first time after power up you can step through the installation
wizard.
5. Enter the necessary data on each page and click Next.
6. On the last screen click Finish to activate the VSAT profile.
For more detailed information about the setup tasks see chapter 4, Setup of the antenna.

SAILOR XTR Ka 4.5W/9W
Installation manual
for 100 cm and 60 cm antennas
Document number: 98-175666-A
Release date: 29 November 2021

98-175666-A iii
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.cobhamsatcom.com,
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.
Company address
Thrane & Thrane A/S, Lundtoftegårdsvej 93D, DK-2800, Kgs. Lyngby, Denmark
Copyright
© 2021 Thrane & Thrane A/S. All rights reserved.
Trademark acknowledgements
• Some product and company names mentioned in this manual may be trademarks or trade names of
their respective owners.
Disposal
Old electrical and electronic equipment marked with this symbol can contain substances
hazardous to human beings and the environment. Never dispose these items together with
unsorted municipal waste (household waste). In order to protect the environment and
ensure the correct recycling of old equipment as well as the re-utilization of individual
components, use either public collection or private collection by the local distributor of old
electrical and electronic equipment marked with this symbol.
Contact the local distributor for information about what type of return system to use.
GPL notification
The software included in this product contains copyrighted software that is licensed under the GPL/LGPL.
The verbatim licenses can be found online at:
http://www.gnu.org/licenses/old-licenses/gpl-2.0.html
http://www.gnu.org/licenses/old-licenses/lgpl-2.1.html
For the parts of our software that fall under the GPL/LGPL licenses, you may obtain the complete
corresponding source code from us for a period of three years after our last shipment of this product,
which will be no earlier than 2027, by sending a money order or check for DKK 50 to:
SW Technology/GPL Compliance,
Cobham SATCOM (Thrane & Thrane A/S),
Lundtoftegaardsvej 93D
2800 Lyngby
DENMARK
Write "source for product SAILOR XTR Ka" in the memo line of your payment. This offer is valid to anyone
in receipt of this information.
https://www.cobhamsatcom.com/legal/free-and-open-source-software-foss/

98-175666-A iv
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. Thrane & Thrane A/S assumes no liability for the customer's
failure to comply with these requirements.
SAILOR 1000 XTR Ka (100 cm)
Microwave radiation hazards
During operation the Above Deck Unit (antenna) in this
system radiates Microwave Power.This radiation may be
hazardous to humans close to the Above Deck Unit. During
transmission, make sure that nobody gets closer than the
recommended minimum safety distance.
The minimum safety distance to the antenna reflector on the
focal line is 30 m for SAILOR 1000 XTR Ka 4.5W, and 55 m
for SAILOR 1000 XTR Ka 9W, based on a radiation level of
10 W/m2. No hazard exists >18° below the antenna’s
mounting plane. Refer to the drawing below.
No-transmit zones
In order to protect
personnel no-transmit
zones can be
programmed. For further
information see
Blocking zones with
azimuth and elevation
on page 3-5.
Distance to other
equipment
Do not move the
antenna closer to radars
than the minimum safe
distance specified in
section Interference
from radar, GPS/GNSS,
L-band and other
MICROWAVE RADIATION
No personnel within safety distance

98-175666-A v
transmitters on page 2-16 – it may cause damage to the antenna.
Compass Safe Distance:
SAILOR 1000 XTR Ka 4.5W and 9.0W antenna (ADU): min. 140 cm (IEC 60945).
SAILOR 7516A BDU (Below Deck Control Unit): min. 30 cm (IEC 60945).
SAILOR 7023A GMU (GX Modem Unit): min. 40 cm (IEC 60945).
SAILOR 600 XTR Ka (60 cm)
Microwave radiation hazards
During operation the antenna in this system radiates
Microwave Power.This radiation may be hazardous to
humans close to the antenna. During transmission, make sure
that nobody gets closer than the recommended minimum
safety distance.
The minimum safety distance to the antenna reflector on the
focal line is 30 m for SAILOR XTR Ka 4.5W, and 44 m for
SAILOR XTR Ka 9.0W, based on a radiation level of 10 W/m2.
No hazard exists >28° below the antenna’s mounting plane.
Refer to the drawing below.
No-transmit zones
In order to protect
personnel no-transmit
zones can be programmed.
For further information see
Blocking zones with
azimuth and elevation on
page 3-5.
Distance to other
equipment
Do not move the antenna
closer to radars than the
minimum safe distance
specified in section
Interference from radar,
GPS, L-band and other
transmitters on page 3-13
– it may cause damage to
the Above Deck Unit.
MICROWAVE RADIATION
No personnel within safety distance
28°

98-175666-A vi
Compass Safe Distance:
SAILOR 600 XTR Ka 4.5W and 9.0W antenna (ADU): min. 140 cm (IEC 60945).
SAILOR 7516A Below Deck Unit (BDU): min. 30 cm (IEC 60945).
Service
User access to the interior of the BDU is prohibited. Only a technician authorized by Cobham
SATCOM may perform service - failure to comply with this rule will void the warranty. Access to
the interior of the Above Deck Unit is allowed. Replacement of certain modules and general
service may only be performed by a technician authorized by Cobham SATCOM.
Grounding, cables and connections
To minimize shock hazard and to protect against lightning, the equipment chassis and cabinet
must be connected to an electrical ground. The BDU must be grounded to the ship. For further
grounding information see the respective sections and appendix in this manual.
Do not extend the cables beyond the lengths specified for the equipment. The cable between
the BDU and Above Deck Unit can be extended if it complies with the specified data
concerning cable losses etc.
Rx and Tx cables for the system are shielded and should not be affected by magnetic fields.
However, try to avoid running cables parallel to high power and AC/RF wiring as it might cause
malfunction of the equipment.
Power supply
SAILOR 7516A BDU: Voltage range 100-240 VAC. The ADU is powered by the BDU.
SAILOR 7023A GMU: Voltage range 100-240 VAC.
Do not operate in an explosive atmosphere
Do not operate the equipment in the presence of flammable gases or fumes. Operation of any
electrical equipment in such an environment constitutes a definite safety hazard.
Keep away from live circuits
Operating personnel must not remove equipment covers. Component replacement and internal
adjustment must be made by qualified maintenance personnel. Do not replace components
with the power cable connected. Under certain conditions, dangerous voltages may exist even
with the power cable removed. To avoid injuries, always disconnect power and discharge
circuits before touching them.
Failure to comply with the rules above will void the warranty!

98-175666-A vii
About this manual
Intended readers
This is an installation manual for the SAILOR XTR Ka system (100 cm and 60 cm) intended for installers of
the system and service personnel. Personnel installing or servicing the system must be properly trained
and authorized by Cobham SATCOM. It is important that you observe all safety requirements listed in the
beginning of this manual, and install the system according to the guidelines in this manual.
Manual overview
This manual has the following chapters:
•Introduction
•Installation
•Interfaces
•Setup of the antenna
•Installation check lists
•Service
This manual has the following appendices:
•Technical specifications
•Dual antenna solution
•Miscellaneous
•Command line interface
•Inmarsat GX satellites
•Grounding and RF protection
•Event messages
•Approvals
Software version
The manual covers the software version 3.03.
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 > LAN”.
Italic is used to emphasize the paragraph title in cross-references.
Example: “For further information, see Connecting Cables on page...”.

98-175666-A viii
Warnings, Cautions and Notes
Text marked with “Warning”, “Caution”, “Note” or “Important” show the following type of data:
•Warning: A Warning is an operation or maintenance procedure that, if not obeyed, can cause injury
or death.
•Caution: A Caution is an operation or maintenance procedure that, if not obeyed, can cause damage
to the equipment.
•Note: A Note gives information to help the reader.
•Important: A text marked Important gives information that is important to the user, e.g. to make the
system work properly. This text does not concern damage on equipment or personal safety.
General precautions
All personnel who operate equipment or do maintenance as specified in this manual must know and
follow the safety precautions. The warnings and cautions that follow apply to all parts of this manual.
WARNING! Before using any material, refer to the manufacturers’ material
safety data sheets for safety information. Some materials can be
dangerous.
CAUTION! Do not use materials that are not equivalent to materials specified
by Cobham SATCOM. Materials that are not equivalent can cause
damage to the equipment.
CAUTION! The system contains items that are electrostatic discharge sensitive.
Use approved industry precautions to keep the risk of damage to a
minimum when you touch, remove or insert parts or assemblies.

98-175666-A ix
Table of contents
Chapter 1 Introduction
1.1 SAILOR XTR Ka system ...........................................................................................................1-1
1.2 Part numbers and options ....................................................................................................1-9
Chapter 2 Installation
2.1 What’s in the box ........................................................................................................................2-1
2.2 Site considerations ....................................................................................................................2-2
2.3 Installation of the ADU (100 cm) ................................................................................ 2-20
2.4 Installation of the ADU (60 cm) ................................................................................... 2-24
2.5 Installation of the BDU ....................................................................................................... 2-28
2.6 Installation of the modem ................................................................................................ 2-28
2.7 To connect the ADU, BDU and modem .................................................................. 2-29
2.8 Integration of a 3rd party IP device (100 cm) .................................................. 2-30
2.9 Power and startup .................................................................................................................... 2-32
Chapter 3 Interfaces
3.1 Connector panel of the BDU ..............................................................................................3-1
3.2 Interfaces of the modem ......................................................................................................3-5
Chapter 4 Setup of the antenna
4.1 Introduction to the web interface ................................................................................4-2
4.2 Settings ...............................................................................................................................................4-6
4.3 Service ............................................................................................................................................... 4-26
4.4 Keypad and menus of the BDU ..................................................................................... 4-36
4.5 Startup sequence ..................................................................................................................... 4-40
Chapter 5 Installation check lists
5.1 Installation check list: Antenna .......................................................................................5-1
5.2 Installation check list: BDU, connectors and wiring ........................................5-2
5.3 Installation check list: Functional test in harbor ...............................................5-3
Chapter 6 Service
6.1 Built-in test and LEDs ...............................................................................................................6-1
6.2 Removal and replacement of the BDU .......................................................................6-2
6.3 Removal and replacement of ADU modules ..........................................................6-2
6.4 Troubleshooting basics ...........................................................................................................6-3
6.5 Returning units for repair ......................................................................................................6-4
Appendix A Technical specifications

Table of contents
98-175666-A x
A.1 Specifications (100 cm antenna) ....................................................................................A-2
A.2 Specifications (60 cm antenna) .......................................................................................A-4
A.3 Patents .................................................................................................................................................A-6
A.4 Outline drawings ..........................................................................................................................A-7
Appendix B Dual antenna solution
B.1 Introduction ....................................................................................................................................B-1
B.2 Installation of the dual antenna solution ................................................................B-1
B.3 Configuration of the dual antenna solution ...........................................................B-4
B.4 Flow chart for installation of the dual antenna solution .............................B-8
B.5 Dual antenna splitter cable .................................................................................................B-9
Appendix C Miscellaneous
C.1 Performance optimization for blockage ....................................................................C-1
Appendix D Command line interface
D.1 Supported connection modes ...........................................................................................D-1
D.2 List of commands ........................................................................................................................D-2
Appendix E Grounding and RF protection
E.1 Introduction to grounding ................................................................................................... E-1
E.2 Grounding Recommendations ........................................................................................... E-2
E.3 Jumper cable for grounding ................................................................................................. E-9
Appendix F Event messages
F.1 Overview ............................................................................................................................................. F-1
F.2 List of events .................................................................................................................................. F-2
Appendix G Inmarsat GX satellites
Appendix H Approvals
H.1 CE (RED) ..............................................................................................................................................H-1
H.2 Inmarsat type approval ..........................................................................................................H-2

98-175666-A 1-1
Chapter 1
Introduction 1
This chapter has the following sections:
•SAILOR XTR Ka system
•Part numbers and options
1.1 SAILOR XTR Ka system
The SAILOR XTR Ka is a unique stabilized maritime GX antenna system operating in the Ka-
band (17.7 to 30 GHz). It is used with the Global Xpress service from Inmarsat, delivering
consistent high-performance download speeds of up to 50 Mbps and 5 Mbps over the
uplink. The following figure shows the coverage map of the GX service.
The system requires a single 50 Ohm coaxial cable to provide the antenna (ADU) with both
DC power, data and control information. The radome does not have to be removed neither
before nor after the installation. To protect the ADU the built-in motors act as brakes during
transport and when the ADU is not powered. You can access the SAILOR XTR Ka remotely
and make in-depth performance analysis using the built-in web interface.
Figure 1-1: GX coverage map
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0°
10°
20°
30°
40°
50°
60°
70°
80°
90°
10°
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30°
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50°
60°
70°
80°
90°
0°20°40°60°80°100°120°140°160°180° 20° 40° 60° 80° 100° 120° 140° 160° 180°
Extendable Global Xpress
coverage via steerable beams
GX1 GX4GX3 GX2 GX5Global Xpress network available
over at least 99% of this area

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-2
The following figures show the SAILOR XTR Ka system.
System features
Single 50 Ohm coax cable for the ADU
One Touch Commissioning
GX-R2 support, wideband and dual polarisation.
Standard 4.5W or High Power 9W BUC.
Gyro-free operation
Ka-to-Ku-band conversion
Dual antenna operation to minimize blocking issues
SNMP traps, IoT and syslog support for real-time monitoring
REST API
Remote service access via FleetBroadband, Iridium, LTE or other IP connection
Remote or local simultaneous software update of ADU and BDU via PC and Internet
browser
Built-in test equipment (BITE) for troubleshooting purpose
BDU with 5 x LAN, NMEA 0183, RS-232 and RS-422, TX Mute
GMU with 8+2 LAN, RS-232 and RS-422 and I/O connector.
No scheduled maintenance.
Few spare parts, easy to service
Support for Cobham ConnectIT
Prepared for third-party IP devices in ADU
The system is set up using the built-in Installation wizard.
Figure 1-2: ADU, BDU and GMU
Above Deck
Unit (ADU)
Below Deck Unit (BDU)
GX Modem Unit (GMU)

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-3
Service friendly system
The system configuration is saved in several modules, there is no loss of data at repair.
There is a switch in the ADU to turn off the power to the antenna. All modules have an LED
status indicator. Each module is encapsulated in a metal box with self-contained mounting
bolts. If necessary, belts and modules can be exchanged through the service hatch on site
for the 100 cm antenna.
You can do remote diagnostics and service. The built-in test equipment of the antenna
checks constantly the antenna modules for proper functioning, it monitors and logs
information for all modules. The ADU performs a POST (Power On Self Test) and you can
request a self test (PAST, Person Activated Self Test). Continuous Monitoring (CM) is always
enabled. Error codes are read out in the web interface and in the display of the BDU. ADU
software is updated automatically when making a software update through the BDU.
1.1.1 Above Deck Unit (ADU)
The SAILOR XTR Ka ADU is a 103cm or 60 cm VSAT 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 and can be used in environments with elevations of -18° to
+118° for 100 cm and -28° to +120° for 60 cm. The 100 cm antenna weighs 105 kg, the
60 cm antenna weighs 37 kg. The antenna is powered by the BDU and protected by a
radome. All communication between the ADU and the BDU passes through a single
standard 50 Ohm cable (with N connector) through the rotary joint. No cable work is
required inside the radome. The 100 cm antenna has 4 LAN connectors and a DC power
outlet in the ADU to connect third-party equipment. The antenna comes with lifting
brackets pre-mounted.

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-4
Modules in the ADU (100 cm)
1. GNSS module (GPS, GLONASS, BEIDOU).
2. XTR Antenna Control Module (ACM).
3. ADU power on/off.
4. Cross elevation motor.
5. Elevation motor.
6. Ka-band transceiver.
7. Inertial Sensor Module (ISM).
Figure 1-3: SAILOR XTR Ka (100 cm): ADU modules 1/2

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-5
8. Azimuth motor.
9. Azimuth zero reference module.
10. Rotary joint.
11. Feed horn.
Figure 1-4: SAILOR XTR Ka (100 cm): ADU modules 2/2

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-6
Modules in the ADU (60 cm)
1. GNSS module (GPS, GLONASS, BEIDOU).
2. XTR Antenna Control Module (ACM).
3. ADU power on/off.
4. Cross elevation motor.
5. Elevation motor.
6. Ka-band transceiver.
7. Inertial Sensor Module (ISM).
Figure 1-5: SAILOR XTR Ka (60 cm): ADU modules 1/2

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-7
8. Azimuth motor.
9. Azimuth zero reference module.
10. Rotary joint.
11. Feed horn.
12. Azimuth motor driver.
1.1.2 Below Deck Unit (BDU)
The BDU contains all user interfaces and manages all communication between the ADU and
the connected VSAT modem, a connected PC and an optional FleetBroadband service
communication line. The BDU comes in a 19” rack version, it has a display, status LEDs and a
keypad. It provides a DHCP server and client mode. The BDU provides DC power to the ADU
through a single coaxial cable. The BDU has the following interfaces:
Figure 1-6: SAILOR XTR Ka (60 cm): ADU modules 2/2
Figure 1-7: BDU, connector overview

SAILOR XTR Ka system
98-175666-A Chapter 1: Introduction 1-8
The BDU has a an On/Off power switch and a LAN connector at the front for accessing the
service port. The unit is AC powered.
1.1.3 GX Modem Unit (modem)
The modem (GMU) comes in a 19” rack version. The modem has the following interfaces
and switch:
• 8 + 2 ports, one active for modem control and user equipment.
• 3 x F connectors for Rx and Tx cables (75 Ohm) to ACU (Rx2 not active).
• RS-422 interface for modem control.
• 2 x RS-232 interfaces, one for modem control, one not active.
BDU connector ID Type Function
NMEA0183 RJ-45 Vessel gyro input
GPIO RJ-45 General Purpose I/O
LAN 1 RJ-45 VSAT modem
LAN 2 RJ-45 User LAN
LAN 3 RJ-45 User LAN
LAN 4 RJ-45 User LAN
RS 232 RJ-45 VSAT modem serial interface
RS422 RJ-45 VSAT modem serial interface
TX In F VSAT modem TX (75 Ohm)
RX Out F VSAT modem RX (75 Ohm)
Antenna N ADU signal and power (50 Ohm)
LAN RJ45 Front LAN service port (LAN 5)
Table 1-1: BDU connectors
Figure 1-8: BDU front panel
465
31.75
482.6
On/Off switch Service port
Figure 1-9: GMU (connector panel)
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GMU

Part numbers and options
98-175666-A Chapter 1: Introduction 1-9
• I/O connector for Tx Mute and Rx Lock.
• Ground wing nut.
• AC Power connector.
• On/Off power switch (at the front).
1.1.4 Satellite type approvals
For a list of satellite type approvals see the SAILOR XTR Ka product page at
www.cobhamsatcom.com.
1.1.5 Service activation
Before you can start using the SAILOR XTR Ka, you need to activate the system for VSAT
service. Contact your service provider for activation.
1.2 Part numbers and options
1.2.1 Applicable model and part numbers
The following model and part numbers are available for the SAILOR XTR Ka system:
1.2.2 Options
The following options are available for the SAILOR XTR Ka system:
Part number Model number Description
407509C-00540 7509C SAILOR 1000 XTR Ka 4.5W ADU
407509D-00540 7509D SAILOR 1000 XTR Ka 9.0 ADU
407506A-00540 7506A SAILOR 600 XTR Ka 4.5W ADU
407506D-00540 7506D SAILOR 600 XTR Ka 9.0W ADU
407516A-00500 7516A SAILOR XTR BDU
407023A-00500 7023A SAILOR Global Xpress Modem Unit GMU
Table 1-2: Model and part numbers for the SAILOR XTR Ka system
Part number Description
407090A-950 Antenna cable 50 m N-Conn (not mounted), male/male
407090A-925 Pigtail Cable 1.25 m, N-Conn, female/male
407090-001 SAILOR 1m SMART Heater, operation down to -55 C
(for 100 cm)
Table 1-3: Model and part numbers for options of the SAILOR XTR Ka system