Codan 4916L-W/E-DC/EX-CE-NI User manual

© 12-50176-EN Issue 2, December 2010 Page 1 of 18
Head office Asia Pacific EMEA Americas
Codan Limited
ABN 77 007 590 605
81 Graves Street
Newton SA 5074
AUSTRALIA
Telephone [phone]
Facsimile [phone]
www.codan.com.au
Codan Limited
81 Graves Street
Newton SA 5074
AUSTRALIA
Telephone [phone]
Facsimile [phone]
[email protected]
Codan (UK) Ltd
Unit C4 Endeavour Place
Coxbridge Business Park
Farnham Surrey GU10 5EH
UNITED KINGDOM
Telephone [phone]
Facsimile [phone]
[e-mail]
Codan Satcom
(Locus Microwave, Inc.)
176 Technology Drive, Suite 200
Boalsburg PA 16827
USA
Telephone [phone]
Facsimile [phone]
[e-mail]
INSTALLATION
Ku-Band BUC systems
Overview
Codan provides a range of BUCs of varying power ranges that operate in basic
single-BUC systems or redundancy systems. These BUCs operate in the
C-Band and Ku-Band frequency ranges. For information on the C-Band and
Ku-Band ranges of products see Application Notes 17-60114 and 17-60115
respectively.
These installation instructions describe cabling and mechanical fitting
guidelines. They are applicable to single-stream Ku-Band BUC installations.
These instructions provide the following information:
• general installation requirements
• a complete list of the contents of each kit
• mounting drawings with instructions
For technical setup and operating information, see specific Application Notes
on the Codan web site or the Satcom Technical Information CD.
4916L-W/E-DC/EX-CE-NI
4908L-W/E-DC/EX-CE-NI
4916-W/E-DC/EX-CE-NI
4908-W/E-DC/EX-CE-NI
4916-MINIBUC
4908-MINIBUC

Ku-Band BUC systems
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Unpacking the equipment
On receiving your BUC system, check the contents against the packing list. Make sure
that all equipment itemised on the packing list is present and that there is no damage to
the equipment before you start installing the equipment.
If anything is missing or damaged, please contact your nearest Codan office immediately
to obtain the correct warranty service procedures. This ensures prompt assistance,
minimal turnaround time, and avoids any freight issues.
We recommend that the equipment is installed by qualified and experienced personnel,
to the relevant standards and approvals.
Installing the BUC equipment
For information on electromagnetic compatibility requirements and safety notices,
please see the reference manual for the product.
WARNING
All equipment that is mounted outdoors must be adequately
weatherproofed.
Use self-amalgamating tape to seal connectors and cable entry points,
from the connector to the cable sheath (see Application Note: Sealing
N-type and MS connectors in satellite equipment installations, 17-60094).
Ensure all W/G joints are properly sealed with the appropriate gasket (see
Application Note: Waveguide gasket kits, 17-60128).
CAUTION Water is the most common cause of poor performance in VSAT
installations. Ensure that all cables and W/G junctions are properly sealed.
WARNING A radiation hazard exists if the BUC is operated with its RF output
unterminated.
WARNING The BUC must be installed in a restricted access location with appropriate
warning signs displayed.
CAUTION Codan disclaims any liability or responsibility for the results of improper
or unsafe installation practices.

Ku-Band BUC systems
12-50176-EN Issue 2, December 2010 Page 3 of 18
Figure 1: Installation flow chart
Install BUC system
as per mounting instructions.
Earth the equipment.
Seal all cable connections.
Align the antenna to the main lobe of the satellite and
set the polarisation angle in accordance with
manufacturer’s instructions and satellite provider.
Tighten all fasteners and brackets.
Secure cables with cable ties.
Seal all access doors and covers.
Check that the power is on, and the equipment is
transmitting traffic.
Install antenna as per manufacturer’s instructions.
Install power to the site.
Install any other mounting structures.
Connect the equipment together
using appropriate cables.
Set up the indoor and outdoor equipment
to station parameters.
See page 12, Essential risk management for
safeguarding personnel, protecting equipment,
and dissipating lightning
See instructions provided with mounting kits and
page 4, General guidelines for installing single-
BUC systems
See Application Note: Setting up and operating
a BUC using serial commands, 17-60118
See Application Note: Installation information for
RF subsystems, 17-60122
See Application Note: Sealing N-type and MS
connectors in satellite equipment installations,
17-60094 (provided in Kit, Connector Sealing
(15-40202))
See page 10, Typical BUC system
configurations
See page 8, Cable installation

Ku-Band BUC systems
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General guidelines for installing single-BUC systems
TRF and LNB
A TRF may already be integrated as part of the antenna feed. In this case, the LNB is
mounted directly to the Rx port of the antenna feed; please check the manufacturer’s
specifications. If the antenna feed does not have an integrated TRF, a TRF must be
installed on the Rx port of the antenna feed, and then the LNB is mounted onto the TRF.
The LNB obtains the required +15 to +24 V DC power and, in certain cases the 10 MHz
reference signal, from a compatible L-Band modem. The modem is connected to the Rx
output connector of the LNB.
BUC
BUCs are supplied with W/G outputs and an optional pole or universal boom mounting
kit suitable for the Codan range of L/M/RBUCs. Contact your antenna manufacturer if
you have specific installation requirements.
It is recommended that BUCs are installed as close as possible to the antenna feed to
minimise losses.
BUCs with W/G output are usually connected to the antenna feed with flexible W/G.
Care should be taken to minimise stress on the flanges due to bends or twists. However,
if the W/G output of the BUC is attached to a rigid connection, ensure that there are no
undue stresses on the W/G section when the flange hardware is tightened. Tighten the
BUC mounting screws last.
IF cables
Use an IF coaxial cable to connect the modem Tx output to the BUC IF input. It is
recommended that you use the same type of cable to connect the modem Rx input to the
LNB.
CAUTION Heavier BUCs may need to be mounted further down the boom to
minimise the mechanical leverage load on the antenna.

Ku-Band BUC systems
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M&C
For remote monitor and control of the ODU, you can use a 6570 Remote Controller, or a
computer connected to the serial interface or the LAN interface (RBUCs only).
If you are using a 6570 Remote Controller, use the cable supplied with the 6570.
If you are using the serial interface, use an M&C cable to connect the BUC to a
computer.
If you are using the LAN interface, use the LAN RBUC/Controller M&C
(Indoor/Outdoor) cable to connect the RBUC to a computer. A temporary connection to
the serial interface is required to set up the LAN interface in an RBUC.
Power supply units
The 6580B PSU is mounted on the pole at the base of the antenna with the mounting
hardware supplied. DC may be supplied to the BUC via the BIAS-T connector on the
6580B using the Tx IF coaxial cable, or via the AUX terminal connectors for externally
powered BUCs.
The DuraComm®IDU PSU is rack-mounted indoors, requiring suitable DC cables to be
run to the outdoor equipment for externally powered BUCs. DC may also be supplied to
the BUC via the BIAS-T connector on the PSU using the Tx IF coaxial cable.
The 7580 is mounted on the pole or boom below the BUC. The pole or universal boom
mounting kit is used for mounting the PSU.
NOTE For more information on the M&C interfaces see Application Note: M&C
interface diagrams of the BUC and 7586L Controller, 17-60132.
NOTE The 6560 and 6570 can be used for monitoring and controlling a BUC
only. They cannot monitor or control the 7586L.

Ku-Band BUC systems
Page 6 of 18 12-50176-EN Issue 2, December 2010
DC-powered BUCs
The BUCs can be DC-powered from:
• an L-Band modem or an appropriate PSU via the IF cable to the IF INPUT
connector on the BUC (up to 16 W)
• an appropriate PSU via a separate DC power cable to the DC INPUT connector on
the BUC (BUCs with external power connector only)
If you need to make your own DC power cable, or re-terminate the cable supplied,
Table 1 lists the pin connections and describes the input functions available on the
DC INPUT connector on the BUC.
WARNING
Before applying power to the BUC, ensure that the installation complies
with the safety precautions listed in the reference manual provided with
the equipment.
NOTE
The DC INPUT connector may be one of the following (or equivalent),
depending on the build standard of the BUC:
• VGL Allied 62IN-12E8-2P
• SungJin SVG02A 16-11P
Table 1: Pinouts of the DC INPUT connector
Pin Description
A Positive (+48 V DC)
BEarth(0V)

Ku-Band BUC systems
12-50176-EN Issue 2, December 2010 Page 7 of 18
AC-powered BUCs
AC-powered BUCs operate with an AC input voltage in the range 115 to 240 V AC.
Check BUC specifications for the exact voltage range of your BUC.
If you need to make your own AC mains cable, or re-terminate the cable supplied,
Table 2 lists the pin connections and describes the input functions available on the
AC INPUT connector on the BUC.
WARNING Voltages outside of these limits may cause damage to the BUC.
Table 2: Pinouts of the AC INPUT connector (Amphenol T 3110 000)
Pin Description
1Neutral
2 Not connected
3 Active
Protective earth
NOTE The supplied cable has a free end. Terminate a suitable AC mains plug for
your region or country.

Ku-Band BUC systems
Page 8 of 18 12-50176-EN Issue 2, December 2010
Cable installation
Where required, you must use standard shielded Codan cables for the power and control
cabling to ensure safety and EMI/EMC standards are met.
In installations where the cables are not supplied by Codan, all power and control cables
must be assembled in accordance with drawings supplied by Codan.
General guidelines
Use the most direct route possible for the cable runs. Secure the cable runs with cable
ties or other suitable clamps.
You may install the indoor/outdoor interconnecting cables underground (in 75 mm PVC
pipe, for example), or supported by an overhead catenary wire. If the transmit and
receive IF coaxial cables are identical, mark the cables at each end before you install
them. Also, ensure that there is enough slack left to make antenna adjustments without
straining the cables.
Securing cables
Once connections have been made, it is important to secure cables so they do not hang
loosely or flap in the wind.
To ensure water drains off the cables and not onto the connections, create a loop in each
cable that hangs lower than the connectors.
CAUTION Loose hanging cables tend to elongate over time, causing the conductors
to stretch and the performance of the cables to degrade.
CAUTION The cables should be secured in such a way that water falling on the
cables does not run directly onto the connections.

Ku-Band BUC systems
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Sealing the connectors
After the equipment has been set up and tested to your requirements, seal all connections
of the BUC and antenna feed according to Application Note: Sealing N-type and MS
connectors in satellite equipment installations, 17-60094 (provided in Kit, Connector
Sealing (15-40202)), and Application Note: Sealing waveguide connections, 17-60128.
Poor sealing of connections is the most common cause of ODU faults.
Without correct sealing the following can occur:
• In most cases, water causes an attenuated signal with intermittent LNB faults or
intermittent powering down of the BUC. This progresses until complete failure of
the connection occurs.
• Water within a connection may be drawn into the cable by capillary action.
• Water (and sometimes dust) within a connection or cable attenuates the signal.
• In extreme cases, water causes a short circuit and corrosion within the connection or
cable.
If water has entered a connection, remove the cable and thoroughly dry out the bulkhead
connector before attaching a new cable and sealing the connection. Ensure there is no
corrosion on the connector. If corrosion is present, replace the connector.
For effective sealing you must use self-amalgamating tape made of PIB or EPR.
Manufacturers include 3M (Type 23 Scotch Self-Amalgamating, Black) and Rotunda
(2517 Self-Amalgamating, Black).
CAUTION Ensure all joints are completely weatherproof.
NOTE Unused connectors should have their protective caps fitted and sealed.
WARNING
Ensure you follow all the sealing precautions in this section during
installation. If the modules or cable connections are not sealed correctly,
the equipment may be damaged or the performance of the ODU may
deteriorate over time.

Ku-Band BUC systems
Page 10 of 18 12-50176-EN Issue 2, December 2010
Typical BUC system configurations
Figure 2: BUC with L-Band modem and LNB
M&C
Rx from
antenna
AC mains
Tx to
antenna
L-Band Tx IF,
+24/48 V DC power
(DC-powered BUC only),
10 MHz Ref, FSK M&C
L-Band Rx IF,
+15 V DC power (nominal),
10 MHz Ref *
RS232/422/485
M&C
L-Band
Modem
TRF
BUC
LNB
External AC power
connector or
+48 V DC power
Data
* Certain LNB versions have internal references
and do not require an external 10 MHz reference
LAN M&C
(RBUC only)

Ku-Band BUC systems
12-50176-EN Issue 2, December 2010 Page 11 of 18
Figure 3: BUC with L-Band modem, external in-line PSU, and LNB
See Table 11 on page 17 for details of the dimensions for your BUC.
M&C
Rx from
antenna
AC mains
Tx to
antenna
L-Band Tx IF,
10 MHz Ref,
FSK M&C
L-Band Rx IF,
+15 V DC power (nominal),
10 MHz Ref *
RS232/422/485
M&C
L-Band
Modem
TRF
BUC
LNB
Data
External
in-line
BUC PSU
AC mains
L-Band Tx IF, 48 V DC,
10 MHz Ref, FSK M&C
* Certain LNB versions have internal references
and do not require an external 10 MHz reference
LAN M&C
(RBUC only)

Ku-Band BUC systems
Page 12 of 18 12-50176-EN Issue 2, December 2010
Essential risk management for safeguarding personnel,
protecting equipment, and dissipating lightning
These potential differences may occur:
• if there is a fault in the AC mains reticulation system
• when high power electrical machinery located nearby is switched on or off
• if a lightning strike occurs in the area
It is highly recommended that the antenna metal structures and the cases of the outdoor
equipment be connected together and grounded with earth stakes, or in the case of
rooftop sites be connected to the lightning grid and earth system of the building. The
protective earth screws on the modules provide this protection. This practice also reduces
the likelihood of the mains supply or RF interfering with the LAN and serial interface
signals, noise interference to the IFL, and ESD protection.
In the case of lightning strikes, large ground currents occur for several hundred metres
around a strike area, causing large voltage potentials between separate earth points. For
this reason, some lightning engineers recommend the use of large copper earth straps (at
least 4 mm2cross-sectional area), or braid, to connect the indoor and outdoor equipment
earth systems.
The consequences of unprotected system installations include loss of revenue due to:
• downtime of the system
• corrupted data and/or total loss of data
• damage to equipment, including the possibility of fire
• overcoming electrical hazards for personnel
WARNING
Precautions must be taken to ensure the installation is adequately
protected against voltage potential differences that may occur between the
outdoor and indoor equipment.
WARNING Equipment must be earthed in a star configuration. The centre connection
of the star must be bonded to the main earth for the site.
WARNING For critical installations in lightning-prone areas, it is strongly advised
that you seek expert advice on lightning protection.

Ku-Band BUC systems
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Kits
Mounting kits
Table 3: Kit, Boom Mounting, Universal to 100 W (15-42072-000)
Description Component part number
Channel, Mounting (qty 2) 05-06876
Rod, Threaded M8 × 250 mm (qty 4) 05-06904
Bracket, Mounting (qty 2) 05-07272
Spacer (qty 8) 05-07273
Rod, Threaded M8 × 180 mm (qty 4) 05-07826
Fitting Instruction, Boom Mounting, Universal to 100 W 15-42072-001
Nut, M8, Stainless steel, Hex (qty 36) 32-00800-080
Washer, M8, Stainless steel, Flat (qty 36) 32-00801-080
Washer, M8, Stainless steel, Spring (qty 36) 32-00801-280
Bolt, M8 × 50, Stainless steel, Hex (qty 4) 32-00850-080
Table 4: Kit, Mounting, 8” to 12“ Pole, RBUC, C/Ku (15-42098-000)
Description Component part number
Rod, Threaded, M8 × 250 mm (qty 4) 05-06904
Rod, Threaded, M8 × 400 mm (qty 4) 05-06984
Bracket, Mounting (qty 2) 05-07533
Fitting Instruction, Mounting, 8”to 12”Pole, RBUC,
C/Ku
15-42098-001
Nut, M8, Stainless steel, Hex (qty 25) 32-00800-080
Washer, M8, Stainless steel, Flat (qty 25) 32-00801-080
Washer, M8, Stainless steel, Spring (qty 25) 32-00801-280
Bolt, M8 × 50, Stainless steel, Hex (qty 6) 32-00850-080

Ku-Band BUC systems
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Table 5: Kit, Mounting, 8” Pole, PSU (15-40128)
Description Component part number
Rod, Threaded, M8 × 250 mm (qty 4) 05-06904
Bracket, Mounting (qty 4) 05-07532
Fitting Instruction, PSU/Controller 15-40128-001
Nut, M8, Stainless steel, Hex (qty 18) 32-00800-080
Washer, M8, Stainless steel, Flat (qty 22) 32-00801-080
Washer, M8, Stainless steel, Spring (qty 14) 32-00801-280
Screw, M8 × 50, Stainless steel, Hex (qty 4) 32-00850-080
Table 6: Kit, Mounting, 12” Pole, PSU (15-40147)
Description Component part number
Rod, Threaded, M8 × 375 mm (qty 4) 05-06984
Bracket, Mounting (qty 4) 05-07533
Fitting Instruction, 12”Pole, PSU/Controller/SSPA 15-40147-001
Nut, M8, Stainless steel, Hex (qty 16) 32-00800-080
Washer, M8, Stainless steel, Flat (qty 20) 32-00801-080
Washer, M8, Stainless steel, Spring (qty 12) 32-00801-280
Screw, M8 × 50, Stainless steel, Hex (qty 4) 32-00850-080
Washer, M12, Stainless steel, Flat (qty 4) 32-01201-080

Ku-Band BUC systems
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Flange kits
Table 7: Kit, Flange, WR75, Thick groove (15-40172)
Description Component part number
Nut, M4, Stainless steel, Hex (qty 5) 31-24000-080
Washer, M4, Stainless steel, Normal (qty 10) 31-24001-080
Washer, M4, Stainless steel, Spring (qty 5) 31-24001-580
Screw, M4 × 10, Stainless steel, Socket cap (qty 5) 31-24010-901
Screw, M4 × 12, Stainless steel, Socket cap (qty 5) 31-24012-980
Screw, M4 × 16, Stainless steel, Socket cap (qty 5) 31-24016-980
Gasket, W/G, Circular cross-section, 3/32, WR75 78-23024
Table 8: Kit, Flange, WR75, Universal (15-40174)
Description Component part number
Nut, M4, Stainless steel, Hex (qty 5) 31-24000-080
Washer, M4, Stainless steel, Normal (qty 5) 31-24001-080
Washer, M4, Stainless steel, Spring (qty 5) 31-24001-580
Screw, M4 × 10, Stainless steel, Socket cap (qty 5) 31-24010-901
Screw, M4 × 12, Stainless steel, Socket cap (qty 5) 31-24012-980
Screw, M4 × 16, Stainless steel, Socket cap (qty 5) 31-24016-980
Gasket, W/G, Rectangular cross-section, WR75 78-23022
Gasket, W/G, Circular cross-section, 1/16, WR75 78-23023
Gasket, W/G, Circular cross-section, 3/32, WR75 78-23024

Ku-Band BUC systems
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Sealing kits
Table 9: Kit, Connector Sealing (15-40202)
Description Component part number
Application Note, Sealing N-type and MS connectors in
satellite equipment installations
17-60094
Tape, Vinyl Elec 19 mm × 6 m 30-39301-007
Tape, Self-amalgamating 19 mm, Wide 30-39304-002

Ku-Band BUC systems
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Drawings
Use these drawings as a guideline for installing your products.
Table 10: Mounting drawings
Title Codan part number
Boom Mounting, Universal to 100 W (BUC) 15-42072-001 (sheet 1)
Boom Mounting, Universal (7580 PSU) 15-42072-001 (sheet 2)
Pole Mounting, 8" to 12", RBUC, C/Ku 15-42098-001
PSU/5586 8" pole 15-40128-001
PSU/SSPA 12" pole 15-40147-001
Table 11: Interface control drawings
Title Codan part number
LBUC, Ku-Band 01-01192
LBUC with fan, Ku-Band 01-01828
MBUC M1, Ku-Band, 16 W 01-01302
MBUC M1, Ku-Band, 25 W 01-01689
RBUC, DC, Ku-Band 01-01785

Ku-Band BUC systems
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15-42072-001 (sheet 1)

15-42072-001 (sheet 2)