COBHAM SAILOR XTR GX-R2 User manual

SAILOR XTR GX-R2
Installation manual

98-175666-D i
SAILOR XTR GX-R2
Quick guide
Installation wizard
This quick guide is for experienced service personnel who have installed the SAILOR XTR GX-R2
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 GX-R2:
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 3, Setup of the antenna.
Figure -1: Installation wizard

SAILOR XTR GX-R2 4.5W/9W
Installation manual
SAILOR 1000 XTR GX-R2 and
SAILOR 600 XTR GX-R2
Document number: 98-175666-D
Release date: 22 May 2023

98-175666-D 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
© 2023 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.

98-175666-D iv
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:
https://www.gnu.org/licenses/old-licenses/gpl-2.0.html
https://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 GX-R2 in the memo line of your payment. This offer is valid to
anyone in receipt of this information.

98-175666-D v
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.
Microwave radiation hazards
During transmission 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.
SAILOR 1000 XTR GX-R2
The minimum safety distance to
the antenna reflector on the focal
line is 30 m for SAILOR 1000 XTR
GX-R2 4.5W, and 55 m for
SAILOR 1000 XTR GX-R2 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.
MICROWAVE RADIATION

98-175666-D vi
SAILOR 600 XTR GX-R2
The minimum safety distance to
the antenna reflector on the
focal line is 30 m for SAILOR 600
XTR GX-R2 4.5W, and 44 m for
SAILOR 600 XTR GX-R2 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 – azimuth and elevation on page 2-6.
Distance to other equipment
Do not move the Above Deck Unit closer to radars than the minimum safe distance
specified in section Interference from radar, GPS/GNSS, L-band and other transmitters on
page 2-14 — it may cause damage to the Above Deck Unit.
Compass Safe Distance:
SAILOR 1000 XTR GX-R2 4.5W and 9.0W antenna (ADU): min. 150 cm (IEC 60945
SAILOR 600 XTR GX-R2 4.5W and 9.0W antenna (ADU): min. 150 cm (IEC 60945).
SAILOR 7516A BDU (Below Deck Unit): min. 30 cm (IEC 60945).
SAILOR 7023A GMU (GX Modem Unit): min. 40 cm (IEC 60945).
SAILOR 7523A GMU (GX-R2 Modem Unit): min. 40 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
MICROWAVE RADIATION

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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 7523A 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-D viii
About this manual
Intended readers
This is an installation manual for the SAILOR XTR GX-R2 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. 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.
SAILOR XTR GX-R2 variants in this manual
The following variants of the SAILOR XTR GX-R2 system are described in this manual:
• SAILOR 1000 XTR GX-R2 4.5W BUC
• SAILOR 1000 XTR GX-R2 9W BUC
• SAILOR 600 XTR GX-R2 4.5W BUC
• SAILOR 600 XTR GX-R2 9W BUC
In the installation chapter the antennas are also named S1000 and S600.
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
•Grounding and RF protection
•Event messages
•Inmarsat GX satellites
•Approvals
Software version
The manual covers the software version 3.09.
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”.

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• 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...”.
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-D x
Table of contents
Chapter 1 Introduction
1.1 SAILOR XTR GX-R2 system ........................................................................... 1-1
1.2 Part numbers and options ......................................................................... 1-11
Chapter 2 Installation
2.1 What’s in the box ........................................................................................... 2-1
2.2 Site considerations ....................................................................................... 2-3
2.3 Installation of the ADU (S1000 antenna) .................................................. 2-18
2.4 Installation of the ADU (S600 antenna) .................................................... 2-22
2.5 Installation of the BDU ............................................................................... 2-26
2.6 Installation of the modem ......................................................................... 2-31
2.7 Installation of the 7523A GX-R2 Modem Unit (SMB3315) ...................... 2-31
2.8 Installation of the 7023A GX Modem Unit (CX-751) ................................ 2-35
2.9 Integration of a 3rd party IP device .......................................................... 2-41
2.10 Power and startup ...................................................................................... 2-43
Chapter 3 Setup of the antenna
3.1 Introduction to the web interface .............................................................. 3-2
3.2 Settings ........................................................................................................... 3-7
3.3 Service .......................................................................................................... 3-31
3.4 Keypad and menus of the BDU .................................................................. 3-42
3.5 Startup sequence ........................................................................................ 3-46
Chapter 4 Installation check lists
4.1 Installation check list: Antenna .................................................................. 4-1
4.2 Installation check list: BDU, connectors and wiring ................................ 4-2
4.3 Installation check list: Functional test in harbor ..................................... 4-3
Chapter 5 Service
5.1 Built-in test and LEDs ................................................................................... 5-1
5.2 Removal and replacement of the BDU ....................................................... 5-2
5.3 Removal and replacement of ADU modules .............................................. 5-2
5.4 Troubleshooting basics ................................................................................ 5-3
5.5 Returning units for repair ............................................................................ 5-4
Appendix A Technical specifications
A.1 Specifications SAILOR 1000 XTR GX-R2 ......................................................A-2
A.2 Specifications SAILOR 600 XTR GX-R2 ........................................................A-6

Table of contents
98-175666-D xi
A.3 Specifications SAILOR XTR BDU 7516A .....................................................A-10
A.4 Specifications SAILOR GX-R2 Modem Unit 7523A ...................................A-11
A.5 Patents ..........................................................................................................A-12
A.6 Outline drawings .........................................................................................A-13
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 Dual antenna splitter cable .......................................................................B-11
Appendix C Miscellaneous
C.1 Performance optimization for blockage ....................................................C-1
C.2 Dual modem operation .................................................................................C-3
Appendix D Command line interface
D.1 Connection modes ........................................................................................D-1
D.2 List of commands ..........................................................................................D-1
Appendix E Grounding and RF protection
E.1 Introduction ...................................................................................................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 (SAILOR 1000 XTR GX-R2) ..................................H-2
H.3 Inmarsat type approval (SAILOR 600 XTR GX-R2) .....................................H-3
H.4 Chinese MITT Order 32 (China-RoHS 2) .....................................................H-4
H.5 Brazilian approvals .......................................................................................H-5

98-175666-D 1-1
Chapter 1
Introduction 1
This chapter has the following sections:
•SAILOR XTR GX-R2 system
•Part numbers and options
1.1 SAILOR XTR GX-R2 system
The SAILOR XTR GX-R2 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 Above Deck Unit
(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 GX-R2 remotely and make in-depth performance analysis using
the built-in web interface.
Figure 1-1: GX coverage map
jÄÇüàõÇü¹èøº¯á¯øÚÇá¹èøàĆÇèáõċøõèü¯üèáÚĝá«áèºċøáĆ¯¯ÇüºÇĖ¯áè¹¤¤ċø¤ĝèøĨĆá¯üü¹èøõøĆǤċÚøċü¯ůèĖ¯øº¯Çüüċ£Ó¯¤ĆĆè¤ÄắĆáĝĆÇà¯ů(Úè£Úõø¯üü¤èĖ¯øº¯FĝIJİIJİů
0°
10°
20°
30°
40°
50°
60°
70°
80°
90°
10°
20°
30°
40°
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 GX4GX3GX2 GX5 Global Xpress network available
over at least 99% of this area

SAILOR XTR GX-R2 system
98-175666-D Chapter 1: Introduction 1-2
The following figure shows the SAILOR XTR GX-R2 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 4 LAN, RS-232 and RS-422 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 GX-R2 system
98-175666-D 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 SAILOR 1000 XTR GX-R2 antennas.
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.

SAILOR XTR GX-R2 system
98-175666-D Chapter 1: Introduction 1-4
1.1.1 Above Deck Unit (ADU)
The SAILOR XTR GX-R2 ADU is a 103 cm or 65 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 -20° to +120° for SAILOR 1000 XTR GX-R2 and -20° to +128° for SAILOR
600 XTR GX-R2. The SAILOR 1000 XTR GX-R2 antenna weighs 113 kg, and the SAILOR
600 XTR GX-R2 antenna weighs 44 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 antenna has 4 LAN connectors and a
DC power outlet in the ADU to connect third-party equipment.The SAILOR 1000 XTR
GX-R2 antenna comes with lifting brackets pre-mounted. The SAILOR 600 XTR GX-R2
comes with a sling pre-mounted.
Modules in the ADU (SAILOR 1000 XTR GX-R2)
1. GNSS module (GPS, GLONASS, BEIDOU).
2. XTR Antenna Control Module (ACM).
3. ADU power on/off.
Figure 1-3: SAILOR 1000 XTR GX-R2 ADU modules 1/2

SAILOR XTR GX-R2 system
98-175666-D Chapter 1: Introduction 1-5
4. Cross elevation motor.
5. Elevation motor.
6. GX-R2 Ka-band transceiver
7. Inertial Sensor Module (ISCM).
8. Azimuth motor.
9. Azimuth zero reference module.
10. Rotary joint.
11. Feed horn.
Figure 1-4: SAILOR 1000 XTR GX-R2: ADU modules 2/2

SAILOR XTR GX-R2 system
98-175666-D Chapter 1: Introduction 1-6
Modules in the ADU (SAILOR 600 XTR GX-R2)
1. Cross elevation motor.
2. Elevation motor.
3. GX-R2 Ka-band transceiver.
4. Inertial Sensor Module (ISM).
5. Azimuth Motor.
Figure 1-5: SAILOR 600 XTR GX-R2)ADU modules 1/2
3
4
2
1
5

SAILOR XTR GX-R2 system
98-175666-D Chapter 1: Introduction 1-7
6. Azimuth Zero Reference Module.
7. Rotary joint. (not visible in photo).
8. Feed horn.
9. XTR Antenna Control Module (ACM).
10. ADU power on/off.
11. GNSS module (GPS, GLONASS, BEIDOU).
Figure 1-6: SAILOR 600 XTR GX-R2: ADU modules 2/2
8
6
7
9
10
8

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98-175666-D Chapter 1: Introduction 1-8
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:
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.
Figure 1-7: BDU, connector overview
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
RS-422 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