COBHAM SAILOR 800 VSAT Use and care manual

Field Replacement Procedure
Following legal entities are trading as / doing business as Cobham SATCOM
Thrane and Thrane A/S, Kgs. Lyngby, Denmark
Sea Tel Inc., Concord USA
TracStar Systems Inc., Orlando, USA
Omnipless Manufacturing (Pty) Limited, Cape Town, RSA
www.cobham.com/satcom
SAILOR 800 VSAT –6W BUC replacement procedure
Brief Summary:
Troubleshooting document for inspecting and replacing the BUC on the SAILOR 800 antenna.
Theory of Operation:
The BUC converts the L-band Intermediate Frequency (IF) up to Ku-band radio signal, and amplifies it to transmit
power level. It receives transmit signal and power from VIM.
Troubleshooting:
TX Test SAILOR 800
Cobham SATCOM
Global Customer Service dept.
Document no.: 97-149715-A
Revision: A
Date: 10-12-2015

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Cable Calibration –output power check.
1: In the menu Service go to Calibration.
2: Click “START” to run the Cable Calibration
3: See that Status changes to “Calibration running”
4: Go to the dash Board.
5: See that the “BUC output power” goes from zero to two bars and back to zero
6: Above will be performed 5 times. (Cable calibration is done using 5 different frq’s.)
7: After the calibration has been performed, take a note of the “Attenuator margin”
8: Attenuator margin:
Max cable loss: 20db. Att margin: 11db. Actual “worst case” cable loss: 20db – 11db = 9db

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CW (Continues Wave) test / 1db compression point
1: Call the hub operator to perform the CW (Continues Wave) test.
2: Start modem application / open telnet-SSH to modem
3: Force the modem to tune to the chosen VSAT beam that will be used for the line-up.
4: Force the modem to listen for this beam and to send the ABS command to the SAILOR 900 VSAT.
5: Wait until the modem gets RX Lock.
6: Activate the line-up when the hub operator asks to do the CW (Continues Wave) test.
7: Enter the Modem CW frequency on the line-up page “Modem CW frequency”
(This will ensure accurate Tx calibration of the SAILOR 900 VSAT).
8: Increase the modem output in steps according to the hub instructions.
9: On the dash board see that “BUC output power” increases along with the increased modem output.
10: The 1 db compression point is normal in the area of -10 to -5 dbm output form the modem.

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Replacing the Block-Up Convertor (BUC):
Tools needed:
•Torx TX20 Screwdriver
•4mm Allen Key
•Flat-Head Screwdriver
•11mm Open Ended Spanner/Wrench
1. Switch off the power to the SAILOR vsat.
2. Open the service hatch.
3. Rotate the antenna pedestal so that the arm with
the GPS module faces the service hatch.
4. Rotate the antenna dish to 90 degrees of elevation
(facing upwards).
5. Press in and turn the elevation locking pin to the
locked position (if applicable).
6. Remove the connector marked “M” from the PMM.
7. Now disconnect the D-sub connector from the
PMM using a small flat-head screwdriver.
8. Disconnect the two F-type / SMB type RF
connectors from the LNBs using an 11mm spanner.
Mark the LNBs after the label on the wires: Co-pol
(left) and X-pol (right).
9. Disconnect the N-type transmit connector.
10. Remove the four 4mm Allen screws to free the
cable spool attached to the PMM, using the 4mm
Allen key. Let the cable spool hang freely.

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11. Disconnect the sensor connector on the OMT.
12. Remove the two 4mm Allen screws on the OMT
and loosen the four 4mm Allen screws on the
Polarisation Unit, using the 4mm Allen key.
13. Manually rotate the polarisation unit clockwise
until its end stop.
14. Rotate the polarisation unit clockwise further in
the key holes and remove it.
*Note: The polarisation unit is attached to the OMT
collar to the feeder horn tube on the rear side of the
unit.
15. Remove the four 4mm Allen screws from the
waveguide flange at the side of the BUC.
16. Loosen the two 4mm Allen screws from the
bracket at the side of the BUC.
17. Slide the BUC to the right to free it from the
Polarisation Unit.
18. Disconnect the N-type transmit cable from the
BUC.
19. To install a replacement BUC follow the
instructions above in reverse order.
20. power up the SAILOR vsat.

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Verify the Initialization of the SAILOR vsat ADU:
After replacing the defective component re-initialize the pedestal and verify its operation.
Reboot the SAILOR vsat (Sw Off / On the ACU)
Now view the pedestal through the service hatch and switch on the service switch located on the rear of the pedestal.
Now verify the Initialization process is as follows:
1. The elevation axis will drive from end-stop to end-stop and then to its zero reference point, with the reflector at 45
degrees. (Elevation zero point)
2. The cross-elevation then drives from end-stop to end-stop and then to its zero reference point, level with the
horizon. (X-elevation zero point)
3. Then the azimuth axis drives one direction and then back on itself before settling at its zero reference point, with
the antenna facing away from the service hatch. (Azimuth zero point)
4. Then the polarization unit axis will drive from end-stop to end-stop and then back to its zero reference point, at
which point the polarization motor module will be at the highest point, with the LNB coax cables pointing left. The
system will then go into ‘ready mode’, expecting to get the satellite tracking parameters from the satellite modem or
systems dashboard.
5. Once the tracking information has been received the system will begin to target the satellite.
6. The above Deck Unit (ADU) then goes from pointing the antenna to then acquiring the signal, and finally into
tracking mode.
7. Verify the system completed the initialization process correctly and that no errors were flagged by the POST.
8: Finally run a cable calibration. Verify that the cable calibration can be performed successful. That will both calibrate
the TX part and verify that the SAILOR vsat can transmit.