Codan 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 Installation Manual

Ku-Band BUC systems

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

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.

© 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]

[e-mail]

Codan (UK) Ltd
Unit C4 Endeavour Place
Coxbridge Business Park
Farnham Surrey GU10 5EH
UNITED KINGDOM
Telephone [phone]
Facsimile [phone]

[e-mail]

INSTALLATION

Codan Satcom
(Locus Microwave, Inc.)
176 Technology Drive, Suite 200
Boalsburg PA 16827
USA
Telephone [phone]
Facsimile [phone]

[e-mail]

Ku-Band BUC systems

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

CAUTION

WARNING

WARNING

CAUTION

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).

Water is the most common cause of poor performance in VSAT
installations. Ensure that all cables and W/G junctions are properly sealed.

A radiation hazard exists if the BUC is operated with its RF output
unterminated.

The BUC must be installed in a restricted access location with appropriate
warning signs displayed.

Codan disclaims any liability or responsibility for the results of improper
or unsafe installation practices.

Page 2 of 18 12-50176-EN Issue 2, December 2010

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

12-50176-EN Issue 2, December 2010 Page 3 of 18

Ku-Band BUC systems

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.

CAUTION

Heavier BUCs may need to be mounted further down the boom to
minimise the mechanical leverage load on the antenna.

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.

Page 4 of 18 12-50176-EN Issue 2, December 2010

M&C

Ku-Band BUC systems

NOTE

For more information on the M&C interfaces see Application Note: M&C
interface diagrams of the BUC and 7586L Controller, 17-60132.

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.

NOTE

The 6560 and 6570 can be used for monitoring and controlling a BUC
only. They cannot monitor or control the 7586L.

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.

12-50176-EN Issue 2, December 2010 Page 5 of 18

Ku-Band BUC systems

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)

Before applying power to the BUC, ensure that the installation complies

WARNING

with the safety precautions listed in the reference manual provided with
the equipment.

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.

The DC INPUT connector may be one of the following (or equivalent),
depending on the build standard of the BUC:

NOTE

• 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)

Page 6 of 18 12-50176-EN Issue 2, December 2010

Ku-Band BUC systems

AC-powered BUCs

AC-powered BUCs operate with an AC input voltage in the range 115 to 240 VAC.
Check BUC specifications for the exact voltage range of your BUC.

WARNING Voltages outside of these limits may cause damage to the 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.

Table 2: Pinouts of the AC INPUT connector (Amphenol T 3110 000)

Pin Description

1Neutral

2 Not connected

3 Active

NOTE

Protective earth

The supplied cable has a free end. Terminate a suitable AC mains plug for
your region or country.

12-50176-EN Issue 2, December 2010 Page 7 of 18

Ku-Band BUC systems

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.

CAUTION

CAUTION

To ensure water drains off the cables and not onto the connections, create a loop in each
cable that hangs lower than the connectors.

Loose hanging cables tend to elongate over time, causing the conductors
to stretch and the performance of the cables to degrade.

The cables should be secured in such a way that water falling on the
cables does not run directly onto the connections.

Page 8 of 18 12-50176-EN Issue 2, December 2010

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.

CAUTION Ensure all joints are completely weatherproof.

NOTE Unused connectors should have their protective caps fitted and sealed.

Poor sealing of connections is the most common cause of ODU faults.

Ensure you follow all the sealing precautions in this section during

WARNING

Without correct sealing the following can occur:

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

• 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).

12-50176-EN Issue 2, December 2010 Page 9 of 18

Ku-Band BUC systems

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)

Typical BUC system configurations

Figure 2: BUC with L-Band modem and LNB

Page 10 of 18 12-50176-EN Issue 2, December 2010

Ku-Band BUC systems

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)

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.

12-50176-EN Issue 2, December 2010 Page 11 of 18

Ku-Band BUC systems

Essential risk management for safeguarding personnel, protecting equipment, and dissipating lightning

Precautions must be taken to ensure the installation is adequately

WARNING

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.

protected against voltage potential differences that may occur between the
outdoor and indoor equipment.

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 mm2 cross-sectional area), or braid, to connect the indoor and outdoor equipment
earth systems.

WARNING

WARNING

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

Equipment must be earthed in a star configuration. The centre connection
of the star must be bonded to the main earth for the site.

For critical installations in lightning-prone areas, it is strongly advised
that you seek expert advice on lightning protection.

Page 12 of 18 12-50176-EN Issue 2, December 2010

Kits

Mounting kits

Ku-Band BUC systems

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

Nut, M8, Stainless steel, Hex (qty 25) 32-00800-080

15-42098-001

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

12-50176-EN Issue 2, December 2010 Page 13 of 18

Ku-Band BUC systems

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

Page 14 of 18 12-50176-EN Issue 2, December 2010

Flange kits

Ku-Band BUC systems

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

12-50176-EN Issue 2, December 2010 Page 15 of 18

Ku-Band BUC systems

Sealing kits

Table 9: Kit, Connector Sealing (15-40202)

Description Component part number

Application Note, Sealing N-type and MS connectors in

17-60094

satellite equipment installations

Tape, Vinyl Elec 19 mm × 6 m 30-39301-007

Tape, Self-amalgamating 19 mm, Wide 30-39304-002

Page 16 of 18 12-50176-EN Issue 2, December 2010

Ku-Band BUC systems

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

12-50176-EN Issue 2, December 2010 Page 17 of 18

Ku-Band BUC systems

This page has been left blank intentionally.

Page 18 of 18 12-50176-EN Issue 2, December 2010

15-42072-001 (sheet 1)

15-42072-001 (sheet 2)

15-42098-001

15-40128-001

15-40147-001

01-01192

CODAN

01-01828

01-01302

01-01689

01-01785