SAILOR 6300MFHF Installation Manual 4

SAILOR 6300 MF/HF DSC
150W/150W FCC/250W/500W
Installation manual
Table of Contents
SAILOR 6300 MF/HF DSC

150W/150W FCC/250W/500W
Installation manual
Document number: 98-130890-D

Release date: November, 2013
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.cobham.com/satcom 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.
Thrane & Thrane A/S is trading as Cobham SATCOM.
Copyright
© 2013 Thrane & Thrane A/S. All rights reserved.
Trademark Acknowledgements
• Thrane & Thrane is a registered trademark of Thrane & Thrane A/S in the European Union and the Unites
States of America.
• SAILOR is a registered trademarks of Thrane & Thrane A/S.
• Other product and company names mentioned in this manual may be trademarks or trade names of their
respective owners.
ii 98-130890-D
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 assumes no liability
for the customer's failure to comply with these requirements.
GROUND THE EQUIPMENT
To minimise shock hazard, the equipment chassis and cabinet must be connected to an electrical ground and the
cable instructions must be followed.
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 service the unit with the power cable connected. Always discon-
nect and discharge circuits before touching them.
Service
General service must be done by skilled service personnel.
Caution! Electric shock hazard. Do not open the equipment. Only skilled service personnel
may service and repair the equipment.
98-130890-D iii
RF exposure hazards and instructions
Your Thrane & Thrane radio generates electromagnetic RF (radio frequency) energy when transmitting. To ensure
that you and those around you are not exposed to excessive amounts of energy and thus to avoid health hazards
from excessive exposure to RF energy, all persons must obey the following:
Caution! Never touch the Antenna Tuning Unit or feeder wire when the MF/HF
MF/HF DSC Telex Aerial MF/HF
radio is transmitting. High voltage which can cause death or serious

injury is present at the locations shown in the illustration below.
250W MF/HF with 6 ch. Scanning SAILOR 608x

DSC Watch receiver Power Supply
SAILOR 6201 SAILOR 6201
Handset Handset
SAILOR 638x
SAILOR 636x Antenna Tuning
Transceiver Unit Unit
(Optional) SAILOR 6209
Accessory SAILOR 630x
SAILOR 6270
Connection Box MF/HF Control Unit
Other Alarm
Distress Alarm (Optional)
SAILOR 6208
SAILOR 6209 Control Unit
Accessory Connection Box
Warranty limitation
Connection Box
The radio is not a user maintainable unit, and under no circumstances should the unit be opened except by authorized
personnel. Unauthorized opening of the unit will invalidate the warranty.
GPS option Telex option
2182 select option
SAILOR 6103 SAILOR 6006 SAILOR H1252B
Alarm Panel Message Terminal Printer
Switch
Box SAILOR 6001
Keyboard
99-131805-C
iv 98-130890-D
Record of revisions
Rev. Description Relase Date Initials
A Original document January 2011 CMA
B 150 W/250 W FCC added Marts 2011 CMA
C 500 W installation added January 2012 CMA
D Cobham rebranding November 2013 CMA
Preface
Radio for occupational use
The SAILOR 6300 MF/HF DSC fulfils the requirements of the EC directive 1999/5/EC, Radio and Telecommunications
Terminal Equipment and is intended for use in maritime environment.
SAILOR 6300 MF/HF DSC is designed for occupational use only and must be operated by licensed personnel only.
SAILOR 6300 MF/HF DSC is not intended for use in an uncontrolled environment by general public.
Training information (for FCC approved equipment)

The SAILOR 6300 MF/HF DSC is designed for occupational use only and is also classified as such. It must be ope-
rated by licensed personnel only. It must only be used in the course of employment by individuals aware of both
the hazards as well as the way to minimize those hazards.
The radio is thus NOT intended for use in an uncontrolled environment by general public. The SAILOR 6300 MF/
HF DSC has
been tested and complies with the FCC RF exposure limits for Occupational Use Only. The radio also complies
with the following guidelines and standards regarding RF energy and electromagnetic energy levels including the
recommended levels
for human exposure:
• FCC OET Bulletin 65 Supplement C, evaluating compliance with FCC guidelines for human exposure to radio
frequency electromagnetic fields.
• American National Standards Institute (C95.1) IEEE standard for safety levels with respect to human exposure
to radio frequency electromagnetic fields, 3 kHz to 300 GHz
• American National Standards Institute (C95.3) IEEE recommended practice for the measurement of potentially
hazardous electromagnetic fields - RF and microwaves.
Below the RF exposure hazards and instructions in safe operation of the radio within the FCC RF exposure limits
established for it are described.
Warning
Your Thrane & Thrane radio set generates electromagnetic RF (radio frequency) energy when it is transmitting. To
ensure that you and those around you are not exposed to excessive amounts of that energy (beyond FCC allowable
limits for occupational use) and thus to avoid health hazards from excessive exposure to RF energy, FCC OET bulletin
65 establishes an Maximum Permissible SAILOR6301_UM.book Page viii Monday, November 14, 2011 2:06 PM ix
Exposure (MPE) radius of 6 ft. (1.8 m) for the maximum power of your radio (150 W selected) with a whip antenna
having a maximum gain of 3.0 dBi. This means all persons must be at least 6 ft. (1.8m) away from the antenna when
the radio is transmitting.
98-130890-D v
Installation
1. A whip antenna with a maximum power gain of 3 dBi must be mounted at least 12.6 ft. (3.9m) above the highest
deck where people may be staying during radio transmissions. The distance is to be measured vertically from
the lowest point of the antenna. This provides the minimum separation distance which is in compliance with RF
exposure requirements and is based on the MPE radius of 6 ft. (1,8m) plus the 6.6 ft. (2.0 m) height of an adult.
2. On vessels that cannot fulfil requirements in item 1, the antenna must be mounted so that its lowest point is
at least 6 ft. (1.8m) vertically above the heads of people on deck and all persons must be outside the 6 ft. (1.8
m) MPE radius during radio transmission.
• Always mount the antenna at least 6 ft (1.8 m) from possible human access.
• Never touch the antenna when transmitting
• Use only authorized T&T accessories.
3. If the antenna has to be placed in public areas or near people with no awareness of the radio transmission, the
antenna must be placed at a distance not less than 12 ft. (3.6 m) from possible human access.
Failure to observe any of these warnings may cause you or other people to exceed FCC RF exposure limits or create
other dangerous conditions.
Related documents
Title and description Document number
SAILOR 630x MF/HF Control Unit, Installation guide 98-132396
SAILOR 6300 MF/HF Transceiver Unit & Antenna Tuning Unit 150 W/250 W/500 98-133081
W, Installation Guide
SAILOR 6000 MF/HF DSC 150/250/500W, User Manual 98-131070
SAILOR 6300 MF/HF Radiotelex, User Manual 98-132519
SAILOR 6101 and 6103 Alarm Panel, Installation and user manual 98-130981
Emergency call sheet 98-132369
vi 98-130890-D
Table of Contents Table of Contents
Chapter 1 General information
1.1 Introduction ..............................................................................................................................1-1
1.2 Technical data............................................................................................................................1-1
Chapter 2 Installation
2.1 Description..................................................................................................................................2-1
2.2 Mounting the units..................................................................................................................2-1
2.3 Ground connections ..............................................................................................................2-8
2.4 Grounding considerations ..................................................................................................2-9
2.5 Antennas......................................................................................................................................2-11
2.6 DC Power cabling ....................................................................................................................2-17

2.7 Interconnection of units......................................................................................................2-18
2.8 Position and time information...........................................................................................2-24
2.9 Telex operation.........................................................................................................................2-25
2.10 ID Programming........................................................................................................................2-26
2.11 Programming Telex ID ..........................................................................................................2-29
2.12 Configuration ............................................................................................................................2-31
2.13 Final installation check..........................................................................................................2-35
Chapter 3 Technical description
3.1 Control Unit................................................................................................................................3-1
3.2 Transceiver Unit........................................................................................................................3-1
3.3 Control/Intercon module 60-127961...........................................................................3-1
3.4 Synth. and DSC WR module 60-131332 .....................................................................3-1
3.5 RX/EX signal path module 60-122880...........................................................................3-2
3.6 PA and Filters module 60-122881..................................................................................3-2
3.7 PA and Filters module 60-123937 (FCC) ....................................................................3-3
3.8 SMPS module 60-122882 (150 W/250 W)................................................................3-3
3.9 SMPS module 60-126172 (500 W)................................................................................3-3
3.10 SMPS module 60-126236 (500 W)................................................................................3-4
98-130890-D vii
Table of Contents
3.11 Transceiver unit block diagram .........................................................................................3-5
3.12 Transceiver unit interconnection diagram...................................................................3-7
3.13 Antenna Tuning Unit .............................................................................................................3-9
3.14 Power control and protection system............................................................................3-11
Chapter 4 Service
4.1 Preventive maintenance ......................................................................................................4-1
4.2 Cleaning the Air filter (500 W Transceiver only).......................................................4-1
4.3 System test and verification...............................................................................................4-2
4.3 Software update.......................................................................................................................4-2
Chapter 5 Spare part exchange
5.1 Disassembling the Transceiver Unit (150 W/250 W).............................................5-1
5.2 Disassembling the Transceiver Unit (500 W).............................................................5-2
5.3 Transceiver Unit module location....................................................................................5-3
5.4 Module overview......................................................................................................................5-6
5.5 Required service tools............................................................................................................5-10
5.6 Accessory list.............................................................................................................................5-10
Glossary .................................................................................................................... Glossary-1
viii 98-130890-D
Chapter 1
Technical data
Chapter 1: General information
General information
General information
1.1 Introduction
The 150 W/250 W/500 W MF/HF transceiver with integrated DSC and telex is designed for maritime
applications in voluntary as well as compulsorily fitted vessels. It offers simplex and semi-duplex SSB
radiotelephone communication in the maritime mobile frequency bands between 1.6 and 30 MHz. The
basic version of the transceiver includes voice, DSC and a dedicated 2187.5 KHz DSC watch receiver,
forming an ideal system for MF GMDSS installations.
The equipment consists of a compact transceiver control unit, a fully remote controlled transceiver unit
and an automatic antenna tuning unit.
The microprocessor controlled Antenna Tuning Unit automatically matches the impedance of antennas
between 8 and 18 metres in length and requires no presetting at the installation. The typical tuning time is
1 s. It is designed for outdoor installation and may be located up to 100 metres from the Transceiver Unit.
The Transceiver Unit contains all receiver and transmitter circuits. The fully protected solid state 150 W/
250 W /500 Wpower amplifier cooled by natural convection matches a 50 ohm antenna system, but
is normally used in connection with the Antenna Tuning Unit. The DSC/Telex modem contains two
demodulators, one connected to the built-in watch receiver for continuous watch on the DSC distress
frequency 2187.5 KHz, the other connected to the communication receiver which may be used to keep
simultaneous watch on other DSC frequencies or may be used for telex communication.
The transceiver can easily be upgraded to include 6 channel scanning DSC watch receiver, and Telex
operation to comply with MF/HF requirements in sea area A3. The upgrade is done by entering software
license codes.
The Control Unit is for operation of radiotelephone as well as DSC and telex functions. Use of the equip-
ment is simple, logic and straight forward. DSC operation is based on the use of soft keys. Guiding texts
are provided and the large display is able to show the contents of a complete call in one screen.
For telex operation the Message Terminal is connected to the system through the CAN bus.
The equipment is designed for operation from a 24 V battery. With the optional AC Power Supply unit
installed the equipment may be supplied from 115/230 V AC main or emergency supplies with automatic
switch-over to 24 V DC supply in the absence of AC supply voltage. Also optionally, a battery charger for
AC is available in the product line.
The built-in test facilities and easy-to-replace module design of the equipment simplifies the service concept.
1.2 Technical data

1.2.1 General
Complies with the relevant IMO performance standards for MF/HF GMDSS equipment, the ITU Radio
Regulations, the ITU-R recommendations and the relevant performance specifications of ETSI, IEC and
FCC, in the ITU marine bands.
Operating modes: Simplex and semi-duplex SSB telephony (J3E), DSC (J2B), AM broadcast
reception (A3E) and Telex (J2B)
Frequency range: Refer to sections concerning specific characteristics
Frequency stability: Better than 0.35 ppm

Warm-up time. Less than one minute
Ageing less than 0.1 ppm/year
Normal operating
temperature: from 0°C to +40°C
Extreme operating
temperature: From -15°C to +55°C
98-130890-D Chapter 1: General information 1-1

Technical data
User-programmable
channels: 199 frequency pairs with mode (1-199)
User-programmable
stations: 40 stations with name, MMSI and station channel
Output power: Refer to sections concerning Receiver / Transmitter characteristics
Supply voltage: Nominal 24V DC floating (-10 +30%)

With optional external AC power supply:
115/230V AC 50/60 Hz. Automatic change-over to DC in the absence of AC supply
Power consumption:
Rx, 60 W (approx. at 24V DC) 150 W 250 W 500 W
Tx, SSB speech 175 W 300 W 600 W
Tx, SSB two-tone 300 W 550 W 1100 W
Tx, DSC/TELEX 310 W 600 W 1000 W
Compass safe distance: Compass safe distance in accordance with ISO/R 694 are given below in metres
Standard Steering
Unit
5.4°/H 18°/H
Control Unit 1.2 0.5
Transceiver Unit 0.4 0.2
Antenna Tuning Unit 0.3 0.1
Handset 0.3 0.2
Cradle 1.1 0.7
Loudspeaker 2.2 1.6
IP ratings (estimated):
Antenna Tuner
System Transceiver Unit Control Unit
Unit *
150 W IP43 IP56 IP54
250 W IP43 IP56 IP54
500 W IP20 IP56 IP54
* Antenna cable must be careflly installed to obtain this IP rating
1.2.2 Receiver characteristics

General: Complies with ETSI 300373 in the ITU marine bands.
Reception:
Mode Rx/Tx antenna plug DSC/Telex antenna plug
SSB/AM X
DSC X (Routine calls) X (Distress calls)
Telex X
Frequency range: 150 KHz to 30 MHz
Frequency resolution: 100 Hz by keyboard entry

10 Hz, 100 Hz or 1 KHz search/fine-tune facility is provided

1-2 Chapter 1: General information 98-130890-D

Technical data
Input impedance: Rx/Tx : 50 ohm

The Antenna is matched by the antenna amplifier in the Antenna Tuning Unit
General information
DSC/Telex: 50 ohm
12V DC / 20 mA is available for possible use of active antenna.
Sensitivity: Telephony (J3E): below 11 dBµV for 20 dB Sinad

Broadcast (A3E): below 25 dBµV for 20 dB Sinad
DSC/Telex (J2B): below 0 dBµV
Intermodulation:

Wanted signal Signal
Telephony (J3E) 30 dBµV
Intermodulation level above 80 dBµV
Telex (J2B) 30 dBµV
DSC (J2B) 20 dBµV
Spurious rejection: Signal: above 70 dB
Audio output power: Build-in loudspeaker

Optional loudspeaker output 6 W typical with less than 10 % distortion.
Output intended for 8 ohm loudspeaker.
1.2.3 Transmitter characteristics

General: Complies with ETSI 300373 and FCC or better in the ITU marine bands.
The Transmitter characteristics are with the Antenna Tuning Unit included.
Frequency range: All frequencies in the range 1605 KHz to 30 MHz however by factory
default arranged in the ITU marine bands.
Frequency resolution: 100 Hz
Output power 150 W SSB: ± 1.4 dB into 50 ohm Antenna, voice for a duty cycle less than 55% and
modulation rate greater than 3 baud.
Reduction to 80 W when continuously keyed with duty cycle greater than
55% during 1 min. Automatic power recovery after 1 min.
DSC/Telex:
120 W ± 1.4 dB

Output power 250 W SSB: ±1.4 dB into 50 ohm Antenna, voice for a duty cycle less than 55% and
modulation rate greater than 3 baud.
Reduction to 100 W when continuously keyed with duty cycle grater than
55% during 1 min. Automatic power recovery after 1 min.
DSC/Telex:
160 W ± 1.4 dB

Technical data
Output power 500W SSB: 1.6-4 MHz 400 W PEP +0/-1.4 dB

4-27 MHz 500 W PEP ±1.4 dB into 50 ohm Antenna, voice for a duty cycle
less than 55% and modulation rate greater than 3 baud.
Reduction to 200 W when continuously keyed with duty cycle greater
than 55% during 1 min. Automatic power recovery after 1 min.
DSC/Telex:
285 W ± 1.4 dB
Power reduction: Low power: 20 W PEP
Intermodulation: below -31 dB/PEP
Spurious Emission: below -43 dB/PEP

below -60 dB/PEP (FCC)
Hum and noise: Less than - 40 dB/PEP
1.2.4 DSC Watch receiver characteristics

General: Complies with ETSI 300338 or better.
Reception: DSC/Telex antenna plug.
Frequency range: Scanning the following frequencies if upgraded to include 6 channel scanning
DSC watch receiver:
2187.5 KHz, 4207.5 KHz, 6312.0 KHz, 8414.5 KHz, 12577.0 KHz, 16804.5 KHz
Input impedance: DSC/Telex: 50 ohm

12V DC / 20 mA is available for use of active antenna.
Sensitivity: DSC (J2B): below 0 dBµV
Intermodulation: DSC (J2B): Wanted Signal: 20 dBµV

Intermod. level: above 70 dBµV
Spurious rejection: above 70 dB
1.2.5 Antenna Tuning Unit characteristics

General: Complies with ETSI 300373 and FCC or better in the ITU marine bands
Frequency range: 1.6 MHz - 27 MHz
Antenna requirements: 8-18 m wire and/or whip antenna
Antenna tuning: Fully automatic with no presetting
Tuning speed: 0.1 - 8 sec.
Power capability
150W/250W: 350 W PEP into 50 ohm antenna
500W: 600 W PEP into 50 ohm antenna
Extreme operating
temperature: from -25°C to +55°C

Technical data
1.2.6 DSC/Telex modem characteristics
General information
DSC: DSC Equipment class: Class A
Protocols: ITU-R M. 493-13, M. 541-9

Ship’s identity: 9-digit identity number

Navigator interface: According to IEC 61162-1
GLL, RMC, ZDA, GGA, GNS

TELEX: Protocols: ITU-R M. 625-3 (incl. M. 476-5), M. 490,

M. 491-1, and 492-6 NBDP telex in ARQ,
FEC and SELFEC modes
Ship’s identity: 5- and/or 9-digit identity number
1.2.7 Dimensions and weight

Control Unit
6301/02/03: Width: 241 mm (9.5")
Height: 107 mm (4.2")
Depth: 99 mm (3.9")
Weight: 0.82 kg (1.8 lbs)
Transceiver Unit 150 W/250 W

6360/62/63: Width: 390 mm (15.3")
Height: 445 mm (17.5")
Depth: 127 mm (5")
Weight: 19 kg (41.9 lbs)
Transceiver Unit 500 W

6364: Width: 392 mm (15.4")
Height: 507 mm (20")
Depth: 217 mm (8.5")
Antenna Tuning Unit 150 W/250 W

6381/82: Width: 290 mm (11.4")
Height: 500 mm (19.7")
Depth: 80 mm (3.1")
Weight: 3.3 kg (7.3 lbs)
Antenna Tuning Unit 500 W

6383: Width: 401 mm (15.8")
Height: 617 mm (24.3")
Depth: 356 mm (14")
Equipment category: Control Unit: Protected

Transceiver Unit: Protected
Antenna Tuning Unit: Exposed

Technical data

Mounting the Units
Chapter 2
Installation
2.1 Description
Correct installation of the equipment is important for maximum performance and reliability. Antennas
and earth connections must be installed with the greatest care using corrosion resistant materials.
Cable routing shall be made so the cables are protected from physical damage. Sharp cable bends
especially on coaxial cables must be avoided and a sufficient number of clips or straps should be used
to secure the cables.
Installation
2.2 Mounting the units
2.2.1 Mounting the Control Unit (CU)
One Unit shall be connected to the Transceiver Unit using the build-in local bus (CU-TU Bus). The CU may
be mounted up to 100 m from the Transceiver Unit using just a multicable 5 x 2 x 0.5 mm2 screened.
The Control Unit may be tabletop or bulkhead mounted.
Control Units with mounting bracket
Mounting option Drilling plan for bracket

4 x M4 or hole for
self-tapping ø3.9
53mm
71mm
23.5mm 200mm
9mm
247mm
99-131985
Weight:
Control Unit 0.82 kg
Mounting Bracket 0.20 kg
Control unit connector panel

Chapter 2: Installation
98-130890-D 2-1
Mounting the Units
Control Units with flush mounting bracket
Drilling plan Weight:

Flush mount bracket 0.04 kg
R2.5mm x 4
Flush mount template
WARNING:
89mm
227mm
Only use screws supplied with
Remove material from shaded area only!
mounting kit for attaching flush
mounting bracket to Control Unit.
99-132034
Handset for Control Unit

Drilling plan
45
226
135
Space for cable and handset cable
62 75 54
* 120
min. 100
Space for handset access

This Handset has a hook-on/off function,
which is activated by a small magnet embedded Weight:
in the cradle.
The cradle must be installed as illustrated in
Handset for Control Unit 0.4 kg (0.02
order to ensure the hook-on/off functionality lbs)
of the Handset.
39655C
Dimensions are in mm
2-2 Chapter 2: Installation 98-130890-D
Mounting the Units
2.2.2 Mounting the Transceiver Unit (TU)

The Transceiver Unit should be installed in a dry place and consideration should be given to acces-
sibility for servicing. It is important to provide sufficient airspace below, above and in front of the unit
for adequate air circulation through the cooling fins. The drawing below shows the outer dimensions,
mounting possibilities and the minimum distance to other objects, as well as a drilling plan.
Transceiver Unit 150 W/250 W

145
391 88
Installation
2
350
430
1
4 x ø8
Cable fitting 1
360
37955A
1) Space for cable: min. 150 mm
Space for airflow and service: min. 500 mm
98-130890-D Chapter 2: Installation 2-3

Mounting the Units
Transceiver Unit 500 W

Note:
1) Space for cable and airflow: min. 150 mm.
2) Space for service access: min. 200 mm.
3) Space for service access: min. 1000 mm.
All dimensions are in mm.
392
360 217
332 160
479
2)
350
417
3)
28 34
1)
Cable fitting
99-126338
Cable fitting
57.6
70
56 12
80
38417

Mounting the Units
2.2.3 Mounting the Antenna Tuning Unit (ATU)

The ATU may be mounted up to 100 metres from the Transceiver Unit using just one RG-213/U or
better coaxial cable.
The ATU must be installed outside in a convenient position to have good access for sufficient length
of feeder wire to meet the antenna connection point.
Antenna Tuning Unit 150 W/250 W
Installation
80
290
200
1)
76.5
145 6 x ø6.50
2)
164
352
164
170
12
75
3) 50
271
37978
1) Space to nearest overhang: min. 50 mm
2) Space for service access: min. 500 mm
3) Space for cable and service access: min. 200 mm

Mounting the Units
Antenna Tuning Unit 500 W
4-0-32426
1) Distance to metal constructions: min. 150

2) Space for service access: min. 500
3) Space for cable and service access: min. 200
Tolerance: +/- 1 mm
Mounting hole: ø8
Weight: 17 Kg

Mounting the Units
2.2.4 SAILOR 6208 Control Unit Connection Box

The SAILOR 6208 is used to convert the small cable dimension from LTW plug to spring loaded terminals
with strain relief for connection to larger cable dimensions.
The box is used to connect the Transceiver Unit to Control Units and Message Terminal respectively.
The box is fitted with optional 120 ohm CAN-BUS termination.

Drilling Plan
Installation
Weight:
SAILOR 6208 0.5 kg.
2.2.5 SAILOR 6209 Accessory Connection Box

The SAILOR 6209 is used to convert the small cable dimension from LTW plug to screw terminals with
strain relief for connection larger cable dimensions.
The box is used to connect the Transceiver Unit and /or the Control Unit to peripheral equipment e.g.
GPS, external loudspeaker etc.

Drilling Plan
7.50
4 pcs. ø5.50
82.70
100
100 26 11.00 77.70

36998
Weight:
SAILOR 6209 0.4 kg.
The SAILOR 6208 and the SAILOR 6209 may be ordered as accessory. Please find accessory list on the
last page of this manual.

Ground connections
2.3 Ground connections

2.3.1 Antenna Tuning Unit
As the earth connection of a transmitter is a very
important part of the antenna system, it is of the
utmost importance to keep in mind that the earth
connection of the Antenna Tuning Unit must
have the lowest possible RF-impedance. Losses in
the earth connection will result in a decrease in
radiated power which means that the range of the
transmitter will be reduced. In steel ships a 100 x
0.5 mm copper strap as short as possible is con- Copper strap 100 x 0.5mm
nected between the earth terminal at the bottom
80
R3.3
of the Antenna Tuning Unit and two or three 1/2"
or M12 bolts welded to the superstructure. Vessels
50
6.6
constructed of non-conducting materials must be
equipped with a copper earth plate having a mini-
20
mum area of 1 square metre mounted below the
water line. From a copper earth bolt hard soldered 6 Dimensions are in mm.
to the earth plate a 100 x 0.5 mm copper strap is 37872

run, preferably uninterrupted to the earth terminal
at the bottom of the Antenna Tuning Unit.
Should it be necessary to break the copper strap, for example to pass through a deck, two or three 1/2"
or M12 bolts should be used for this feed through. On wooden ships having a superstructure of metal,
this superstructure should also be effectively connected to the copper strap by using stainless steel bolts
and preferably pieces of stainless steel strips between the metal parts. On fibre glass boats, such as yachts
and sailing boats, it may be difficult to install a sufficiently good earth. Short copper straps are bolted
to conducting parts on the engine, the keel and other conducting objects. Many copper straps can be
glued to the inner surface of the hull below the water line to produce a large capacitance to the water.
It is important that the total area of copper is large and that the distance between the copper surface
and the water is as small as possible. The copper straps are connected directly to the ATU.
On ships where the environmental conditions require shielded grounding downlead in order to avoid
radiation from same downlead, it is recommended to use a shielded cable with a non-stranded wire
having adequate wire dimension to securee the proper grounding. Cable shielding should be connected
at ATU mounting kit and left open at the earth connection side.
2.3.2 Transceiver Unit and Control Unit

11mm
The Transceiver Unit is preferably grounded
separately to the ships metal in the shortest
possible way. A 10 to 16mm sq. ground wire
is connected to the ground terminal (cable wire
crimp
clamp) at the bottom of the unit. ø5.4mm
37836

Grounding considerations
2.4 Grounding considerations

Proper system grounding is one of the most important installation details.
Two areas of grounding must be considered:
a) The ground connection between the ATU and earth plane.

b) The ground connection of the TU and the externally connected equipment.
Each area requires separate considerations even though they are interrelated. Ideally the Control Unit,
Transceiver Unit, Antenna Tuning Unit and the antenna ground-plane must have the same RF ground
potential. Unfortunately this situation is seldomly achieved, but interference problems will be reduced
Installation
along with how close to this “ideal” the grounding of the installation is performed.
On some installations ground loops will cause problems. A ground loop is caused by more than one
ground path for a given unit. This will introduce circulating RF currents which may cause malfunction
of other equipment onboard the ship as well as a “hot” handset.
Not OK installation
'Hot' Handset
TU
ATU
CU
RF current loop
Zg
Ground-Plane
37867
2.4.1 Antenna start

The vertical antenna always starts at its electrical ground-plane, whether or not it is physically mounted
there. First determine the antenna’s electrical ground-plane, which is where the ATU must be mounted.
Where possible always take the ATU to the ground, not the ground to the ATU.
In case of a fibreglass boat, the ground-plane may well be at the hull grounding terminal. Then this is
where the Antenna Tuning Unit should go and this is where the antenna actually starts.
OK installation
Not a 'Hot' Handset
TU
CU
ATU
Ground-Plane
The antenna starts here

37868

Grounding considerations
2.4.2 RF ground loop

It is not always possible or practical to mount the ATU using a very short strap to the actual ground-
plane. In such a case the coaxialcable may be connected between units with different ground potentials
causing RF loop-current to flow.
Not OK installation
TU
ATU CU
coaxial cable
Vg = Iant x Zg
Zg RF current loop
Ground-Plane
37869
2.4.3 Minimizing ground loops

By routing the coax cable very close together with the ATU ground strap (secure good RF coupling
between the two) all the way down to the ground-plane, there will be no RF ground loop left to generate
the interference.
OK installation
TU
ATU CU
Vg = Iant x Zg
Zg
coaxial cable
Ground-Plane
37870

Antennas
2.5 Antennas
2.5.1 Transceiver Antenna
The equipment is used with common transmitting and receiving antenna. The antenna should be
erected in the open, away from conducting object such as derricks etc. which may cause reduction of
the radiated power. Insulators should be of the best type having low leakage even when wet. Stays,
wires, steel masts etc. should be either effectively earthed or insulated. The antenna should also be kept
as far away as possible from electrical equipment in order to minimize noise. Electrical installation such
as cable braiding (screens) and instruments in the vicinity of the antenna should be earthed effectively,
Installation
and the instruments in question should be fitted with noise-interference suppression devices, effective
in the range 0.1 MHz to 30 MHz to avoid malfunction of these instruments. The Antenna Tuning Unit
will tune on any frequency in the range 1.6 to 27 MHz to good whip and/or wire installations of 12 to
18 m total electrical length.
Shorter antennas, electrical length down to 8 m can be used. Where possible long antennas should be
installed to maximize the radiated power in the lower frequency bands.
In general a 12 m antenna installation can be made using an 8 meter

whip and 4.5 m feeder or a 10 m whip and 2.5 m feeder. In both cases
the whip should be mounted on a pole allowing for the feeder to be
erected at an angle of no less than 60 degrees to create a vertical
antenna system. Using horizontal feeders or feeders mounted at
an angle below 45 degrees usually transform the antenna radiation
resistance to a lower value reducing the radiated power. Furthermore,
the total antenna system should be kept well away from conductive
objects such as the mast. Usually a horizontal distance of more than
4 meters will create good results.
If a whip antenna is used this should have an anti-corona

ball as a top termination to prevent crackling noise in the
receiver.
Ma
x.
4
me
te
r
er
met
.1
Max
The antenna is terminated at the insulator at the top of the Antenna

Tuning Unit. The insulator must be relieved from mechanical stress
by using max. 1 metre flexible wire between the insulator and a
support. To maximize the radiated power and avoid flash over keep
distance to metal parts as long as possible. All wire junctions in the
antenna system must be made with cable lugs of correct size ac-
cording to the wire gauge. This will prevent bad connections due
to corrosion. For further corrosion proofing grease may be applied
to the cable joints.

Antennas
2.5.2 Recommended ATU installation

On a metal-hull vessel
Install the ATU on an ATU Mounting Kit. The kit is stainless steel which can be bolted or welded to ship's
hull to ensure good and solid connection in the radio system primary ground point.
The mounting kit will at the same time ensure straight and flat mounting for the ATU cabinet and provide
good airflow around the ATU for better heat dissipation.
On a wooden or fibreglass hull vessel

Install the ATU on an ATU Mounting Kit. The kit is stainless steel which can be bolted to ship's hull
and then provide a ground plane connection to ensure good and solid connection in the radio system
primary ground point.
The ground plane should normally be provided in as vide surface as possible with shortest possible con-
nection to ships earth connection to the water surface.
Alternatively and in case of long ground connections the grounding should be arranged in a solid and
shielded cable connection where sufficient cable square material to provide the connection and the
shielding connected to ATU Mounting Kit and left open at earth connection side.
ATU Mounting Kit

An optional ATU Mounting Kit as shown below is available in two versions:
1. Compries mounting plate and fittings for mast - part no. 737589
For mounting the ATU directly on a mast, where the Mounting Plate and fittings for mast can form a
sufficient earth connection on a steel mast welded to the superstructure.
2. Compries the mounting plate only - part no. 737588

To get an even mounting surface on an uneven support.
1 2 3 4 5
6 x mountingholes for Antenna Tuner Unit.
5 Treadrod M10 64.005

4 Mountingplate 237218
3 Fitting for mast 237227
2 Tooth lock washer 1. Nut M10
89.019
1 Nut M10 2. Tooth lock washer M10
88.695
Pos Name Specification
3. 06.10.00 Fitting for mast Supplier specification
DATE SCALE MATERIAL
4. CVE Mountingplate
INIT. 1:3 for ATU
5. Treadrod M10
FINISH
SUBJECT ITEM
A: 06.10.00 CVE
Mountingguide for ATU mountingkit NO. 037590
DRAW.
CORRECTION NO. 3-0-37590A

Antennas
2.5.3 Considerations on antenna length requirements

Antenna impedance
The length of the transmitting antenna used with MF/HF equipment in general and the MF/HF equip-
ment specifically for purpose of this discussion is of utmost importance for the proper performance of
the equipment, i.e. the ability to tune properly to the antenna and the effective transmission range - to
a lesser extend influencing the receiving performance. In terms of transmission range, more important
than increasing the transmitter RF output power from say 150 W to 250 W is in fact the use of an
adequate length antenna.
Comparatively, any practical length whip antenna remains by far too short for the wavelength for which
it is used, especially at the lower frequencies. For the frequency range 1.6 – 30 MHz defining the com-
Installation
mercial MF/HF marine band, the wavelength spans the range 190 – 10 m approximately.
A proper ground plane for the transmitting antenna is essential in order for this to effectively radiate
power into the air. When applying RF energy to the whip antenna, the presence of the aforementioned
ground plane immediately creates a capacitance between the whip antenna and the ground plane.
This capacitance will vary with frequency hence the impedance of the whip antenna as seen from the
transmitter will vary with the frequency range over which the transmitter is operated.
Whip antenna
Capacity is
created when
RF energy is
applied to
aerial
Ground plane

As an illustration of the impedance variation with frequency of a transmitting antenna refer to below
table listing the impedance as measured on a 6, 7 and 8 m whip antenna respectively with a 2 m feed line.
Frequency Transmitting Antenna Transmitting Antenna Transmitting Antenna

(MHz) 6m 7m 8m
1.6 3-j1.310 3-j1.200 4-j1.060
2.0 4-j1.025 4-j970 5-j800
3.0 7-j970 8-j550 9-j470
4.0 9-j410 10-j325 11-j250
5.0 17-j260 18-j200 20-j145
6.0 20-j150 25-j95 28-j38
7.0 35-j65 40-j10 55+j55
8.0 40+j30 50+j90 60+j155
10.0 100+j190 130+j270 200+j400
12.0 600+j450 650+j450 1000+j300
16.0 1000+j200 900-j500 500-j500
18.0 700-j500 400-j500 250-j450
22.0 200-j400 90-j280 70-j80
25.0 90-j195 75-j10 240-j200
30.0 200+j150 500+j0 400-j300
In the figures for the impedance in this table the imaginary part (jxxx) describes the value of capaci-
tance part.
Antennas
Function of the Antenna Tuning Unit (ATU)

The MF/HF transmitter power amplifier (PA) provides a fixed output impedance of 50 ohms over its
operating frequency range to which the load (the antenna) should be matched (i.e. load should prefer-
ably be 50 ohms also) in order for the transmitter to deliver its full power output to the load. However,
with the varying impedance of an antenna, as described above such a condition may only be met at
one or - at best - a few specific frequencies. On the remaining frequencies within the transmission band
the varying mismatch between the transmitter fixed output impedance and the different impedance of
the antenna at any given frequency will result in reduced RF power delivered to the antenna – in worst
case hardly any power at all - if the antenna was connected directly to the transmitter.
To overcome the frequency dependant mismatch between the transmitter output impedance and the
antenna (load) impedance, the ATU is put into the antenna circuit to provide variable compensation
counteracting the varying impedance of the antenna, the end result of which is the “transformation” of
this into a “fixed” app. 50ohms load, as “seen” by the transmitter.
The compensation is achieved mainly through the introduction of an induction in series with the antenna
circuit, the value of which will create a resonance circuit at the given frequency. Hence, depending on
the impedance of the antenna (i.e. the transmission frequency) a suitable combination of inductors from
a bank of inductors in the ATU, are selected through of a number of relays, the activation of which is
controlled by the ATU processor during the tuning process.
MF/HF ATU
For the impedance of e.g. the Comrod AT82 transmitting antenna of 5-j800 ohms at 2 MHz, as stated
by the manufacturer, the ATU will easily tune to the impedance of this antenna system - in fact, the
array of coils in the ATU tuning circuitry allows tuning all the way down to the impedance of 4-j1060
ohms of this antenna system at 1.6 MHz. A slightly shorter antenna system might be used at the possible
sacrifice of the ability to tune at the extreme low end of the frequency band below 2 MHz.
The impedance of the antenna system is however, influenced by any nearby metallic objects such as
vsl's superstructure and/or nearby metal poles/masts or stays/wires. Consequently, in order not to alter
the impedance of the antenna system which may eventually cause difficulties for the ATU to match the
resulting antenna system impedance, the transmitting antenna should be kept at a distance of no less
than 4 m from any such objects. Similarly goes for the feed wire connecting the ATU to the antenna
that this should be kept at a minimum of 1 m distance from metallic objects.
It should be noted that even though the ATU will tune to the mentioned antenna system length, the
effective radiated power (i.e. the efficiency of the antenna) in the low frequency end will suffer as com-
pared to the use of a longer antenna system of recommended electrical length 10-18 m.
Antenna system installation in practice

As will be noted on subject of the impedance figures in above table covering three different lengths of
Comrod transmitter antennas, the measurements were made with the antenna raised on a 2 m steel
pipe over a flat steel roof (ground plane) and a 2 m feed line. This implies that the measured impedance
is in fact that of the actual antenna (electrical) length plus additional 2 m. The electrical length of the
8 m bracket mount (side fed) Comrod transmitter antenna is 6.8 m resulting in a total electrical length
of the antenna system for which above the impedance figures are valid, of 8.8 m.

Antennas
Electrical specifications transmitting antennas
Frequency range 1.6-30 MHz

Power rating 1.5 kW PEP
Impedance See separate section
Polarization Vertical
Pattern Omnidirectional
Electrical length 5.5 m (18 ft) (add 0.5 m (1.7 ft) for base mount)
6.5 m (21 ft) (add 0.5 m (1.7 ft) for base mount)
Installation
7.5 m (25ft) (add 0.5 m (1.7 ft) for base mount
subtract 0.7 m (2.1 ft) for bracket mount)
The connection to the transmitting antenna is by a single ended wire

- the feed line - connecting from the ATU top connector. As is evident
from above this feed line adds to the electrical length of the antenna
(when correctly installed), thus in effect increasing the efficiency of
the antenna. This further implies that the longer the feed line the bet-
ter the efficiency of the antenna system consisting of transmitting
antenna and the feed line.
For direct addition of feed line length to antenna electrical length the
Ma
feed line should be vertically installed as an extension downwards of x.
4
the transmitting antenna. In practice, where the ATU must be placed me
te
r
between the feed line and the ground plane (steel deck), the direct
er
vertical installation of the feed wire may be difficult in terms of total met
.1
Max
height. This may partly be accounted for by allowing the feed wire
installed at an angle of between 45 and 60 degrees with the horizontal
plane. Installing the feed wire at lower angles rather than increasing
the efficiency of the antenna installation will create a capacitance to
the ground plane decreasing the efficiency of the antenna.

Grounding
An equally important issue in the MF/HF system's ability to tune is
the proper grounding of the entire system - and this goes for every
component from the cable screens and -connectors to the equipment’s
bonding to the ground plane.
Failure to make sure that cable screens and connectors are tied properly
together making good uninterrupted screening to equipment ground
potential makes the installation more vulnerable to HF radiation.
Increasing antenna length reduces antenna current which in turn
reduces the risk of unwanted radiation into the equipment. Hence, a
longer antenna may appear to solve a tuning problem which may in
fact has its origin elsewhere.
Retrofit installations
Especially in retrofit situations caution to the adequate grounding should be observed especially when
installing the ATU. Often times several years of paint have been applied to the area where the ATU
is installed and only the exposure of clean bare metal at the grounding point will provide a sufficient
bonding to ground potential/hull.
Before the re-use of existing coaxial cabling etc. is decided these should be inspected for any corrosion
and/or water ingress. Any water ingress in a cable immediately calls for a new cable to be installed.
Any corrosion at the cable ends/connectors must be cut to clean material. If not possible due to limited
excess length of existing cable, cable should be replaced.

Antennas
2.5.4 DSC watch receiver antenna

The DSC watch receiver antenna may be an active or a passive type.
The antenna should be erected well in the clear and kept away as far as possible from electrical equip-
ment in order to minimize noise. Electrical installation such as cable braiding and instruments in the
vicinity of the antenna should be earthed effectively, and the instruments in question should be fitted
with noise-interference suppression devices, effective in the range 0.1 to 30 MHz. The antenna feed-in
should be coaxial cable.
In case of a passive antenna the feed-in should be as short as possible, especially in the case of short
antennas. The recommended antenna length is 7-30 meters. If a long coax cable is necessary an im-
pedance matching transformer should be inserted at the antenna or an active antenna should be used.
DC supply voltage for an active antenna is available at the DSC RX antenna connector. The supply voltage
is +12 V for supply currents up to 20 mA. The short circuit current is limited to 2 mA to allow passive
antennas with matching transformers to be connected directly.

DC Power cabling
2.6 DC Power cabling

The supply leads are connected to the supply terminal strip of the Transceiver Unit. The supply termi-
nal strip is adapted for 3 wire shielded power supply cable to meet international installation and EMC
requirements. The safety ground wire is connected to the left terminal showing ground symbol and
shielding connected to the cable fitting shown in page 2-3 must be well grounded to ships hull.
The earth connection of the equipment will not cause the battery to be earthed. Maximum permissible
peak voltage between the battery terminals and earth is 100 V.
Fusing must be provided in the supply leads.
Installation
Cable lengths stated in tables comprise the total cable length from battery terminals via charger, shunt
box, DC distribution to TU DC-terminals.
Table below shows the necessary cable cross sections and external fuse ratings.
 








150 W/250 W
Max. cable length to Recommended Cable
External fuses
battery* Sceened multiwire
5m 3 x 10 mm² 40 A
8m 3 x 16 mm² 50 A
12 m 3 x 25 mm² 63 A
500 W
Max. cable length to Recommended cable
External fuses
battery* Sceened multiwire
2.5 m 3 x 10 mm² 100 A
4m 3 x 16 mm² 100 A
6m 3 x 25 mm² 100 A

Interconnection of units
2.7 Interconnection of units

Transceiver Unit connector panel
TU-CU BUS AUX SUPPLY ALARM LAN DSC RX RX/TX
24V DC
99-130948
Control Unit connector panel
ACC AUX
LAN
TU-CU BUS
99-130950
150 W/250 W Antenna Tuning Unit connector pane
40631
500 W Antenna Tuning Unit connector panel
TX/RX
TX/RX
TX/RX
TX/RX
99-126340

Control Unit
Handset/ Handset/
98-130890-D
Hand- Hand- Antenna
microphone microphone Control Unit Transceiver Unit Tuning
(Back) (Front) Unit
SUPPLY
Handset ACC AUX LAN TU-CU GND TU-CU BUS LAN 24VDC ALARM AUX RX/TX DSC RX GND RX/TX
2 5 6 7
LTW LTW LTW RJ45 LTW LTW RJ45 LTW LTW PL259 PL259
10 10 12 12 12 5 10
Female Female Female Female Female Female Female RG-213/U
3a
3 4
GPS RG-213/U
(optional)
8 12 3a 15 3a 12 13 10 9
406208A 406208A
406209A Control Unit Control Unit
(optional) Conn. Box Conn. Box
1 406209A
2182 Selc Accessory
(optional) 14 Conn. Box
"Optional/Service"
***) ***) GPS

406208A Message Ethernet
Control Unit
Chapter 2: Installation
Terminal Switch
Conn. Box
11
)
"Optional" TX
**Loud inhibit
speaker Printer (optional)
8 13
12 12 12
External ) AC
Data *Power Supply/
DSC Alarm Modem Battery 24V
Keyboard Panel Battery
Alarms (Remote Charger
(optional) optional) (optional)
*) Please check the accessory list to find recommended power products
**) Please check the accessory list to find recommended loudspeaker
Please note that for distance less than 25 m the system will work with 0.25 mm² instead of 0.5 mm²
***) Please note power separately 99-130929-B
Option
2-19
Installation
Cable 1: Control Unit - ACC

Cable: 10 x LTW-UL2464 26AWG
Cable-connector: 10 way (ex. LTW)
5 m cable with connector supplied
Control
Unit
'ACC' Designation Remarks Color
10 way
LTW
1 NMEA+ NMEA position input Brown
2 NMEA- NMEA position input Blue
3 2182 Select OC output. Low when 2182 kHz is selected White
4 NC No Connection Green
5 MIC Handset microphone Yellow
6 EAR Handset earpiece Grey
7 HOOK PTT Hook and PTT Pink
8 +12 V DC 12 V supply to handset Red
9 GND System ground Black
10 GND System ground Orange
Cable 2: Control Unit - Ground

Recommended wire dimension: min. 2.5 mm2
Maximum length 0.2 m
Cable 3: Control Unit - Transceiver Unit

6 m cable with connectors supplied with equipment
Control Transceiver
Unit Unit
'TU-CU 'TU-CU Tvisted
Designation Remarks Color
BUS' BUS' pair
12 way 12 way
LTW LTW
1 1 a SHIELD Screen connected to system ground Brown
2 2 b GND System ground Blue
3 3 b +24 V Supply voltage for the Control Unit White
4 4 c CAN Vcc CAN supply (15 V DC) Green
5 5 d CAN H CAN data H Yellow
6 6 d CAN L CAN data L Grey
7 7 c CAN GND CAN ground Pink
Supply on signal to the Transceiver Unit
8 8 a SUPPLY_ON Red
Active when connected to GND
9 9 e AUDIO IN+ Black
Balanced Audio IN
10 10 e AUDIO IN- Orange
11 11 f AUDIO OUT+ Violet
Balanced Audio OUT
12 12 f AUDIO OUT- Cyan

Cable 3a: 2nd Control Unit - Transceiver Unit

2 Control Units installed must be connected in a serial CAN-bus installation.
The cable is defined as a CAN-bus Drop-line, max 5 m.
Cable 15 between 2 connection boxes 406208A is defined as CAN-bus backbone and may be up to
100 m using tvisted pair cable 6 x 2 x 0.5 mm² or better.
More than 2 CU's require special installation, please contact a T&T partner for assistance.
Cable 4: Transceiver Unit - Antenna Tuning Unit

Cable: 50 ohm coaxial cable RG213/U (or better)
Maximum cable length 100 m
Installation
Cable-connector: UHF connector PL259, Crimp type connector should be used.
Cable 5: Transceiver Unit - Ground

Recommended wire dimension: min. 10 mm2
Maximum length 0.2 m
Cable 6: Transceiver Unit - DSC/TELEX RX Antenna

Type: 50 ohm coaxial cable RG213/U (or better)
Cable-connector: UHF connector PL259, Crimp type connector should be used.
Cable 7: Antenna Tuning Unit - Ground

Copper strap 100 x 0.5 mm or 3 x 6 mm shielded cable with wires and shielding connected to ATU
GND and shielding left open at the other end.
Refer to section ‘Ground Connections’
Cable 8: Control Unit – External DSC Alarms & External Speaker

6 m cable with connector, available from eShop
Control
Unit
Cable
'AUX' Designation Remarks Color
no.
12 way
LTW
1 NC 10 No Connection Brown
2 NC 11 No Connection Blue
3 NC 11 No Connection White
4 NC 9 No Connection Green
5 OTHER DSC 8 + 5 V output, when active Yellow
ALARM
6 NC 10 No Connection Grey
7 DISTRESS 10 + 5 V output, when active Pink
ALARM
8 GND 9 System ground Red
9 SPEAKER OUT 8 External speaker (max. 6W in 8 ohm) Black
10 NC 10 No Connection Orange
11 NC 11 No Connection Violet
12 NC 12 No Connection Cyan
Cable 9: Transceiver Unit - AUX

Transceiver
Unit
'AUX'
10 way LTW
1 NMEA+ NMEA position input Brown
2 NMEA- NMEA position input Blue
3 GND System ground White
Single ended 600 ohms AF output
4 LINE_OUT Nominal 0 dBm in 600 ohm Green
Refers to system ground (GND)
Single ended 600 ohms AF input
5 LINE_IN Nominal level 0 dBm Yellow
Refers to system ground (GND)
Transmitter inhibit/RX mute input Pulled up to +15 V
6 TX_INHIBIT Grey
Low when TX keyed
7 TX_KEYED Pink
OC output, max. 50 mA, 12 V
+12 V output
8 12V_OUT Red
Max. 50 mA
Transmitter key input. Pulled up to +15 V
9 EXT KEY Black
10 GND System ground Orange
Cable 10: Transceiver Unit - Supply Alarm

Transceiver
Unit
'SUPPLY Designation Remarks Color
ALARM'
5 way LTW
1 AC_ALR* AC Alarm input. Alarm when connected to GND Brown
2 GND System ground Blue
3 VBAT- Black
Voltage input for high/low battery voltage alarm
4 VBAT+ White
5 NC No Connection Green/GND
Cable 11: Message Terminal

Cable: Shielded high quality USB-cable

Cable 12: Ethernet

Cable: STP CAT-5E
Cable 13: Transceiver Unit – 24 V Battery

For power cable information see section 2.6 DC Power Cabling
Cable 14: Message terminal

5 m cable supplied with Telex option kit
Installation
Message
terminal
'NMEA'
5 way LTW
1 System GND GND
2 CAN S CAN Vcc Red
3 CAN C CAN GND Black
4 CAN H CAN H White
5 CAN L CAN L Blue
Cable 15: Control Unit - Transceiver Unit

For extended cable length, use shielded twisted pair cable 6x2x0.5mm2 or better
For connection details refer to wiring table for cable 3.

Position and time information
2.8 Position and time information

2.8.1 Connection of Navigation Equipment
Navigation equipment complying with the NMEA 0183/IEC 61162-1 standard may be connected for
automatic position and time updating. Connection is made to the NMEA+/NMEA- connections in the
Control Unit ACC connector or the NMEA+/NMEA- connections in the Transceiver Unit AUX connector.
The NMEA receive circuit consists of an optoisolator with a 470 ohms series resistor to insure current
mode operation and a shunt diode to limit reverse bias as shown below. The circuit is isolated from ground.
NMEA IN + A The circuit operates with a minimum

differential input voltage of 2 volts
and draws less than 2 mA from the
NMEA IN - B line at that voltage. The maximum
voltage is 15 volts.
37871
Interconnection between devices may be by means of two-conductor shielded twisted-pair cable.

Multiple listeners may be connected to a single talker. The receivers are connected in parallel. The shield
should be connected to the navigator chassis and should not be connected at any listener. However the
shield should be continuous (unbroken) between all listeners.
Supported sentences:
GLL (longitude, lattitude, utc, status, mode)
GGA (longitide, lattitude, utc, quality )
RMC (longitude, lattitude, utc, status, mode)
GNS (longitude, lattitude, utc, mode)
ZDA (utc, day, month, year)
Only the mentioned fields are used - the rest are discarded.
Radios operating SW version 1.05 or higher will accept NMEA data on the LAN-connection.

Telex operation
2.9 Telex operation

The GMDSS Radiotelex Terminal is designed in accordance with relevant IMO, ITU and ETSI recom-
mendation/specifications and has been approved for shipboard installations to be operating within the
Global Maritime Distress and Safety System.
It supports world-wide ship-to-ship, shore-to-ship and ship-to-shore communication by utilizing the

radiotelex protocols described in ITU- Rec. 625 to overcome the deficiencies of the HF medium. In case
of two-way communication an ARQ (Automatic Repetition reQuest) algorithm for error correction is thus
used, and when sending to more than one station an FEC (Forward Error Correction) algorithm is used.
Installation
MF/HF DSC Telex Aerial MF/HF
250W MF/HF with 6 ch. Scanning SAILOR 608x

DSC Watch receiver Power Supply
SAILOR 6201 SAILOR 6201
Handset Handset
SAILOR 638x
SAILOR 636x Antenna Tuning
Transceiver Unit Unit
(Optional) SAILOR 6209
Accessory SAILOR 630x
SAILOR 6270
Connection Box MF/HF Control Unit
Other Alarm
Distress Alarm (Optional)
SAILOR 6208
SAILOR 6209 Control Unit
Accessory Connection Box
Connection Box
GPS option Telex option

2182 select option
SAILOR 6103 SAILOR 6006 SAILOR H1252B
Alarm Panel Message Terminal Printer
Switch
Box SAILOR 6001
Keyboard
99-131805-C

ID programming
2.10 ID programming
2.10.1 Front Panel
1. Loudspeaker.
2. Four soft keys with function title in the display.
3. Large TFT color display.
4. Alphanumerical keys to enter Rx or Tx frequency or text strings.
5. CH button for channel selection.
6. Rx/Tx Key to enter Tx or RX frequency.
7. Connector for handset or handmicrophone.
8. Distress button for sending a Distress alert.
9. RF gain control (IF).
10. Volume knob with key-press function for power on/off.
11. Selector and dim knob with key-press function for radio operation and setup.
12. Mode key to select the work mode: SSB, AM Broadcast, DSC, Telex.
13. Replay button to play back up to 240 s voice messages.

ID programming
2.10.2 Set-up Menu

Menu items shown in bold is only available in the menu structure when it is extended by access password
>1-2-3-4-5< in the System Set-up menu.
Set-up Menu
Soft keys (2) Radio set-up Scan Hang Time
Scan Resume
Scan Mode
External PTT
Installation
LSB Mode: OFF
ATU: Enabled
TX AM 2182: Disabled
1x> Channel Set-up Watch Receiver
Privat Channels
DSC Watch
TX Band
2x> Power Supply Monitor: OFF
3x> DSC Set-up Position & MMSI
DSC Groups
Auto- Ack Test
Auto-Ack Polling
Auto-Ack Position
Auto-Ack Individual
Non-Distr. Inactivity
Distress Inactivity
Comm. Inactivity
Non-Distr. Alarms
Self-Term. Distr. Alarms
Medical Transport
Neutral Crafts
Print DSC
DSC self-test
4x> DSC Call Log Received Distress
Transmitted Calls
Received Calls
5x> System Set-up Printer Configuration
System Time & Date
Inactivity Timeout
Language
Theme
GPS Input
Diagnostics
Factory Defaults
Password
Reset MMSI no
Radio Info
6x> Controller Set-up Handset 1 Vol
Handset 2 Vol
Wheel Lock
High Priority
Controller Set-up
7x> System Config 6 Ch WR: Disabled
Telex: Disabled

ID programming
2.10.3 Change / reset MMSI

MMSI no is requested at ‘first time power up’ and directly programmed via the numeric keyboard (4)
If a MMSI reset or change of registration is needed it is accessed via the Set-up Menu:
Operation Key Operation Function

Press 2 2 x More
2 Set-up
2 5x> System Set-up
Scroll down to 11 Rotate Password
Select 11
Key in 4 1-2-3-4-5
Scroll down to 11 Reset MMSI Number
Select 11 Yes
Key in MMSI 4 9 digits 123456789


Programming Telex ID
2.11 Programming Telex ID

Programming Telex ID is done via the in SAILOR 6006 Message Terminal.
Requires that the Telex option has been enabled in the radio (see ‘Option Code Activation’) and TLX
mode selected on the Control Unit (12).
The MMSI (9 digits) is automatically transferred from radio to SAILOR 6006 Message Terminal when
TLX mode is selected.
5 digit TLX call code and answerback is programmed on screen via the SAILOR 6006 Message terminal.
Installation
Operation Key Action
Press Settings
Identification
Key in Pswd 1-2-3-4
Key in 5 digit call code (1-2-3-4-5)
Press Answer back
Key in Answer back max 20 characters
Press OK
If a 5 digit TLX call code has not been issued or otherwise is not available, insert 5 x 2 (22222) to indi-
cate invalid call code.

Programming Telex ID
Figure Shift (FS), Letter Shift (LS), Carriage Return (CR) and Line Feed (LF) are normally not required
inserted in the answerback.

Configuration
2.12 Configuration
The GMDSS approved radio is by default configured to meet the legislative requirements and restrictions
in regards to what optional functionality may be configured do apply and will normally require national
exemptions to be utilized.
Configuration and test facilities, which are considered ‘user facilities and basic settings’, are available
via the menu structure.
Further configuration possibilities are available behind the access password >1-2-3-4-5< indicating that
any changes in this area will affect the system operation and therefore should be done with caution.
Installation
Press 2 2 x More
2 Set-up
2 5x> System Set-up
Scroll down to 11 Rotate Password
Select 11
Key in 2 1-2-3-4-5
Other configurations considered installation features are accessed via the ‘Radio Service Tool’.
Please refer to ‘SAILOR 6222/6248/6249 VHF and SAILOR 6300 MF/HF Service tool Manual’ –
98-133342, available for download at www.cobham.com/satcom.
2.12.1 CU configuration
Priority setting is via the menu and Main CU is High Priority = ON and Slave CU is High Priority = OFF.

Press 2 2 x More
2 Set-up
2 3x> Controller Set-up
Scroll down to 11 Rotate High Priority
Select 11 Press
Select 11 Rotate High Priority = ON/OFF
Press 2 Exit To store
2.12.2 ATU configuration

ATU is default enabled.
ATU enable/disable is configured via the Radio Service Tool.

Configuration
2.12.3 DSC printing ON/OFF

Press 2 2 x More
2 Set-up
2 3x> DSC Set-up
Scroll down to 11 Rotate Print DSC: OFF
Select 11 Press
Select 11 Select ON/OFF
Any LAN connected printer can now be selected to print DSC messages from the log. Please check ‘DSC
Printer Configuration’.
2.12.4 DSC Printer configuration

Press 2 2 x More
2 Set-up
2 5x> System Set-up
Scroll down to 11 Rotate Printer configuration
Select 11 Press

2.12.5 DSC self test

Menu Key Operation Function
3x> 2 DSC set-up
Scroll 11 DSC Self Test
Press 11 Select RUN
Press 11 To Activate
System start TX test With DSC call on 2187.5 kHz to own WR.
2.12.6 Factory default/reset

Factory default is a ‘User defined’ reset of settings and address books etc.

Press 2 2 x More
2 Set-up
2 5x> System Set-up
Scroll down to 11 Rotate Factory Default
Press 11 Select Continue Factory Reset
Select 2 Yes / No Factory Resetting
Please wait up to 30 sec.
System reboot and Control Unit connecting to radio.

Configuration
2.12.7 Factory reset via service tool

Factory reset will bring all ID and configuration settings in the radio system back to factory level as a
new system and is performed via the Radio Service Tool.
Options already enabled in the system will remain activated. Resetting of options require separate
operation via the Radio Service Tool.
2.12.8 LSB mode configuration
Installation
LSB (Lower Side Band) mode is configured via the Radio Service Tool.
GMDSS radios require SSB operation in USB (Upper Side Band) mode and may only have LSB mode
enabled on a special exemption depending on national requirements where the ship is registered.
Radios installed and operated as ‘non-GMDSS radios’ can have LSB enabled.
2.12.9 Option code activation

6-channel Watch Receiver and Telex functions are optional features and are thus disabled in the radio
as supplied from factory.
Both functions are enabled by inserting a unique 10 digit option code for each via the System Confi-
guration in the Set-up menu:

Press 2 2 x More
2 Set-up
2 6x> System configuration
Select 11 6 CH WR Option Code
Key in DSC6 option code 2 1-2-3-4-5-6-7-8-9-10 Enabled
Scroll down to 11 TLX mode Option Code
Key in TLX option code 4 1-2-3-4-5-6-7-8-9-10 Enabled
The 10 digit option codes for 500 W systems are foc and supplied with equipment (not programmed).
The 10 digit option codes for 150 W/250 W systems may be ordered with the system or any time later.
DSC6 option code part number: 406301-001
TLX option code part number: 406301-001
DSC6 and TLX option codes are unique to each radio, are generated on basis of the TU serial number
and locked to this.
Option codes already generated either through purchase or as foc codes for the 500 W systems may
be looked up in the ‘Configuration Key Search’ at www.cobham.com/satcom.
Options already enabled in a system will remain activated even after ‘Factory default’ and ‘Factory Reset’
operation. To disable these optional functions requires reset of the respective option code using the
Radio Service Tool.
2.12.10 Power Supply monitoring

Power Supply monitoring is by default set ‘OFF’ from factory.
When the Power Supply monitoring is set ‘ON’ the TU ‘Supply Alarm’ connector becomes active and
ready for interconnection to the Power Supply/Charger in order to monitor ‘AC Alarm’ and ‘Battery
High/Low Voltage Alarm’ states.
The Power Supply monitoring function meets the GMDSS requirements for AC fail and Battery voltage
alarms with acoustic and visual indication on the Control Unit.

Configuration

Press 2 2 x More
2 Set-up
2 2x> Power Supply
Select 11 Press Monitor
Scroll 11 Select Enabled/Disabled
Select 11 Press Enabled
Press 2 OK Enabled
Press 2 Exit
Detailed Power Supply and Charger configuration is available in the in the SAILOR 6081 Power Supply
Unit and Charger Installation & User Manual.
2.12.11 Remote mode

Remote mode is configured via the Radio Service Tool and will be part of a future ThraneLINK application
interfaced via LAN.
2.12.12 TX band configuration

Press 2 2 x More
2 Set-up
2 1x> Channel Set-up
Scroll down 11 Rotate TX-Band
Select 11 Press
Press 2 Add New band
Key In Band limits 4 1605,0 The freqs wanted
26175,0
Press 2 Save Free run TX
2.12.13 Watch Receiver settings

Press 2 2 x More
2 Set-up
2 1x> Channel Set-up
Select 11 Press Watch Receiver
2.12.14 Special configuration

Coast station configuration and special facilities are configured via the Radio Service Tool.
Please refer to 'SAILOR 622286248/6249 VHF and MF/HF Service tool Manual' - 98-133342 available
for download at www.cobham.com/satcom.

Final installation check
2.13 Final installation check

Refer to ‘User Manual’ – chapter Service & Preventive Maintenance.
Installation

Final installation check

Chapter 3
Technical description
3.1 Control Unit
The Control Unit consists of a main module 60-127962 and two sub modules: HMI module 60-127963
and the Intercon module 60-127964.
The main module consists of the digital part, i.e. the microprocessor, program FLASH, SDRAM, TU-CU
Bus communication driver and Ethernet interface.
The main module also consists of an analog part, i.e. the voltage regulators, the analog interface circuits
and the analog output drivers (audio and light). The main module supports a build-in speaker and the
connectivity of an external 8 ohm speaker. The module also controls the the graphical TFT color display
(240x320 dots).
The HMI module contains a minor keyboard interface and encoders for volume and rotary knob.
The Intercon module contains the connectors for external interfaces.
3.2 Transceiver Unit

The Transceiver Unit consists of five modules. Three modules located in the base part of the unit: a
control and interconnection module, a receiver/exciter signal path module, and a synthesizer and DSC
RX module including master oscillator, and two modules are located in the door part of the unit: a
power amplifier module including filter bank and a switched mode power supply. The main wiring is by
ribbon cables with Micro MaTch connectors. RF signals are routed in coaxial cables using Taico, MCX
and BNC connectors.
3.3 Control/Intercon module 60-127961

The Control/Intercon module performs the digital portion of the transceiver functions requested by the
Control Unit and contains interconnection circuits. The central part is the CPU. The program software
is contained in Flash. The processor communicates with the CU via the CAN interface, with auxiliary
equipment via an Ethernet interface and the ATU via a modem circuit. Internal communication is via
the TU Bus. At power up the CPU boots the DSP.
The transmitter is monitored via the PA Peak, Filter Peak and Filter Average detectors. An adjustable
opto-isolated battery detector circuit monitors the battery voltage at the Supply Alarm connector and
triggers an alarm when outside the set range. The DSP performs DSC modulator and dual DSC demo-
dulator functions. The modulator output is through a transversal filter.
The DSP performs the analogue control and audio switching allows loop back test.
Audio circuits convert between unbalanced and balanced lines used by the TU-CU Bus.
The Control/Intercon module stores the TU serial number option codes.
3.4 Synth. and DSC WR module 60-131332

The Synthesiser part includes Master oscillator, dividers, 3.LO PLL and VCO, 2.LO filters and multiplier
and 1.LO fractional N system as well as both 1. and 2. DSC LO PLL and VCO. The Master oscillator
generates a
17.8176 MHz reference signal which is distributed to the local Synthesizer LO sub-circuits.
The appropriate frequencies for the MF/HF transceiver are then generated.
The DSC Watch receiver is built up as a Double Super Heterodyne Receiver using intermediate frequen-
cies of 30.155 MHz and 455 kHz.
98-130890-D Chapter 3: Technical description 3-1

After frequency conversion to 455 kHz the signal is fed to 455 kHz IF2 AGC amplifier before led to final
detection / conversion to 1700 Hz.
The Signal is filtered out by 1700 Hz Audio filter and afterwards led to limiting amplifier thus creating
the DSC output for further processing.
The Receiver Signal Path also includes antenna supply and receiver protection circuitry.
A RF splitter divides the DSC antenna signal between the Watch Receiver and the Main Receiver, which
uses the signal in telex mode.
The Synthesizer used for the Watch Receiver consists of the following sub circuits:
• An integer type PLL is used for creating the DSC LO1 signal. The PLL resolution is 2 kHz and after division
by 4 the final DSC LO1 resolution is 500 Hz. Three separate VCO´ s are used for covering the necessary
frequency range. A 14.85 MHz TCXO is used for reference for the PLL.
• A doubler Circuit submitted to the 14,85 MHz reference signal is used for DSC LO2 signal thus creating
29.70 MHz.
• A 14.6144 MHz TCXO divided by 32 thus creating 456.7 kHz is used for DSC LO3 signal.
3.5 RX/EX signal path module 60-122880

The RX signal path includes protection, pre-selection, mixers, IF amplifiers, filter bank, demodulator,
squelch and audio. The RX signal path has Automatic Gain Control. The RX signal path performs the
handling of the received antenna signal and delivers an AF signal, via the Control/Intercon module where
the AF signal is converted from an unbalanced to a balanced signal, to the Control Unit.
The RX signal path also includes a DSC receiver signal path, which uses the MF/HF signal path, until the
last down conversion. DSC part includes a mixer, base band filter and hard limiter. During DSC reception,
the DSC part overrules the normal MF/HF reception.
The EX signal path includes AF compressor, modulator, filter bank, mixers and EX output amplifiers.
The EX signal path has Automatic Loop Control. The EX signal path generates the modulated RF signal,
adjusted to correct level - ALC adjusted signal, to the Power Amplifier.
The RX / EX signal path is controlled by the Control/Intercon module and receives its injection signal
from the Synth./DSC WR module.
3.6 PA and Filters module 60-122881

The PA and Filters module includes PA drivers, PA-stage, protection circuits, bias circuits, key circuit and
five low-pass filters with relays and relay drivers. The PA and Filters receive the modulated RF input signal
from the RX/EX Signal Path and delivers the amplified and filtered output signal to the TX/RX connector
via a receive/transmit relay on the Control/Intercon module.
The low-pass filters remove the unwanted harmonic frequencies from the PA signal. The Filpeak and
PAprotec outputs are monitoring signals for the Control/Intercon module. The driver and final power
amplifier stages are galvanically isolated on input and output as they are supplied directly from the 24
V DC input. The selection of low-pass filter is controlled by the Control/Intercon module.
The PA filters cover the frequency ranges:
1.6 3.1 MHz

3.1 5.0 MHz
5.0 9.0 MHz
9.0 17.0 MHz
17.0 29.7 MHz

3-2 Chapter 3: Technical description 98-130890-D

3.7 PA and Filters module 60-123937 (FCC)

The PA and Filters module includes PA drivers, PA-stage, protection circuits, bias circuits, key circuit and
five low-pass filters with relays and relay drivers. The PA and Filters receive the modulated RF input signal
from the RX/EX Signal Path and delivers the amplified and filtered output signal to the TX/RX connector
via a receive/transmit relay on the Control/Intercon module.
The low-pass filters remove the unwanted harmonic frequencies from the PA signal. The Filpeak and
PAprotec outputs are monitoring signals for the Control/Intercon module. The driver and final power
amplifier stages are galvanically isolated on input and output as they are supplied directly from the 24
V DC input. The selection of low-pass filter is controlled by the Control/Intercon module.
The PA filters cover the frequency ranges:
1.6 2.3 MHz

2.3 3.05 MHz
3.05 4.5 MHz
4.5 8.8 MHz
8.8 16.81 MHz
16.81 19.0 MHz
19.0 30.0 MHz
3.8 SMPS module 60-122882 (150 W/250 W)

The Switched Mode Power Supply supplies the low power circuits of the equipment with the various
stabilized voltages required, and provides galvanic isolation from the supply source. The equipment is
supplied from a 21.6 – 31.2 V DC power source. The module also carries the input filter and PA supply
output which is not galvanically isolated.
The power supply converts the incoming voltage to 7.5 V, +15 V, -15, and 25 V. The SMPS is switched
on from the Control Unit via the TU-CU Bus SUPPLY ON wire and switched off under software control
via the SUPPLY ON/OFF connection from the Control/Intercon module. The DC supply voltage is sensed
by a BAT INFO detector circuit and fed to the Control/Intercon module for automatic RF output power
adjustment.
3.9 SMPS module 60-126172 (500 W)

The Switched Mode Power Supply supplies the low power circuits of the equipment with the various
stabilized voltages required, and provides galvanic isolation from the supply source. The equipment is
supplied from a 21.6 – 31.2 V DC power source. The module also carries a protection circuit for over/under
voltage, wrong polarity and error detection. This circuit operates a relay on SMPS module 60-126136.
The power supply converts the incoming voltage to 7.5 V, +15 V, -15, 25 and 30 V. The SMPS is switched
on from the Control Unit via the Scanbus SUPPLY ON wire and switched off under software control via
the SUPPLY ON/OFF connection from the Control/Intercon module. The DC supply voltage is sensed
by a BAT INFO detector circuit and fed to the Control/Intercon module for automatic RF output power
adjustment.

Transceiver unit block diagram (150W/250W)
3.10 SMPS module 60-126136 (500 W)

This switched mode power supply contains a common input filter for 60-126136 and 60-126172 and
supplies the PA. The input and output are galvanically isolated, and the output is floating with regards
to ground.
The supply for the PA is 45 V, and is switched on with the HT On connection. A reduced voltage for the
PA is available in Telex-mode.
A fan blower control circuit is also employded. As the PA and / or the SMPS heats up, the fans will be
activated. Should the temperature reach unsafe levels, the power for the PA will be switched off.

98-130890-D
24V DC to PA
150 W/250 W
Switched + 7.5 V
Mode - 15 V LP Filters
24V DC Power + 15 V
Supply + 25 V
PA AND FILTERS 60-122881

SMPS 60-122882 /60-123937
DSC WR AF
DSC RX AF
RX AF
TX AF
Transceiver unit interconnection diagram
Converter AF TX AF De- RX AF
AF Switch Switch Compressor Modulator modulator 3. LO
TCXO
PLL VCO and
Dividers
455 kHz DSC
RX AF AF Filter 1700 Hz DSC RX AF
Converter Switch Bank Filter Amp.
2. LO
TU-CU CAN
BUS Filter X5 Filter
AF Amp. AF Amp. CODEC

600 Ohm 600 Ohm
1. LO
PLL API Band
AUX corr. select
DSP
TX Key & Sample Loop VCO
TX Inhibit 45 MHz hold ampl.
Interface Filter
CPU and Gain
Ramp DAC Prescaler
gen.
Chapter 3: Technical description

SUPPLY Detector
ALARM
AGC
LAN generator
TX SIGNAL
TX/RX TU-ATU TX/RX
Modem Switch RX SIGNAL Ant. Pre- EX SIGNAL IF1 Amplifier & IF2 Amplifier & DSC AF
3.11 Transceiver unit block diagram
Switch Selector Protection Frontend filtering filtering IF2 filter Hard DSC WR AF
Circuit Filter AGC amp. Limiter
IF1=30.155MHz IF2=455kHz 1700Hz
32 - 46 MHz 29.7 MHz 456.7 kHz
CONTROL/INTERCON 60-127961 RX/EX SIGNAL PATH 60-122880
Antenna Divide X2 Divide
Supply by 4 by 32
DSC RX
VCO VCTCXO
14.6641 MHz
PLL
VCTCXO
14.8500 MHz
SYNTH. AND DSC WR 60-131332
3-5
99-130853-A
3-6
Switched
Mode
Power
+ 7.5 V
- 15 V
+ 15 V
500 W
+ 25 V
Supply + 30 V
SMPS 60-126172
LP Filters
Switched
24V DC Mode + 45 V
Power
Supply
SMPS 60-126136 PA AND FILTERS 60-125886

DSC WR AF
DSC RX AF
RX AF
TX AF
Converter AF TX AF RX AF
AF Switch Compressor Modulator Demodulator
Switch 3. LO
OCXO
PLL VCO and
Dividers
455 kHz DSC
RX AF AF Filter 1700 Hz DSC RX AF
Converter Switch Bank Filter Amp.
2. LO
TU-CU CAN
BUS Filter X5 Filter
AF Amp. AF Amp. CODEC

600 Ohm 600 Ohm
1. LO
PLL API Band
AUX corr. select
DSP
TX Key & Sample Loop VCO
TX Inhibit 45 MHz hold ampl.

Interface Filter
CPU and Gain
Ramp DAC Prescaler
gen.
SUPPLY Detector
ALARM
AGC
LAN generator
TX SIGNAL
TU-ATU TX/RX
TX/RX Modem Switch RX SIGNAL Ant. Pre- EX SIGNAL IF1 Amplifier & IF2 Amplifier & DSC AF
Switch Selector Protection Frontend filtering filtering IF2 filter Hard DSC WR AF
Circuit Filter AGC amp. Limiter
IF1=30.155MHz IF2=455kHz 1700Hz
32 - 46 MHz 29.7 MHz 456.7 kHz
CONTROL/INTERCON 60-127961 RX/EX SIGNAL PATH 60-122880
Antenna Divide Divide
Supply by 4 X2 by 32
DSC RX
VCO VCTCXO
14.6641 MHz
PLL
98-130890-D
VCTCXO
14.8500 MHz
SYNTH. AND DSC WR 60-122879
99-133445
98-130890-D
X3 X3
GND 1 1 GND
GND 2 2 GND
GND 3 3 GND
GND 4 4 GND
5 5
150 W/250 W
GND GND
GND 6 6 GND
GND 7 7 GND
SUPPLY OFF 8 8 SUPPLY OFF
SUPPLY ON 9 9 SUPPLY ON
BATINFO 10 10 BATINFO
+25V 11 11 +25V
+25V 12 12 +25V
+25V 13 13 +25V
-15V 14 14 -15V
-15V 15 15 -15V
+15V 16 16 +15V
+15V 17 17 +15V
+7.5V 18 18 +7.5V
+7.5V 19 19 +7.5V
GND 20 20 GND
X4 W3 X4
PA+ 1 1 PA+
2 2
PA+ PA+
SMPS 60-122882 PA AND FILTERS 60-122881/60-123927
PA+ PA+
PA+ PA+
PA+ 18 18 PA+
PA+ 19 19 PA+
PA - 20 20 PA -
X5 W4 X5
PA - 1 1 PA -
PA - 2 2 PA -
PA - PA -
PA - PA -
PA - 18 18 PA -
PA - 19 19 PA -
20 20 PA+
PA+
W5
X8 EX SIGNAL
PA PROTEC
X2
STROBE
SUPPLY OFF
BATINFO
FILPEAK
PA TEMP
GND
GND
SUPPLY ON
GND
GND
+15V
+15V
ADR0
ADR1
+ TX SIGNAL
ADR2
ADR3
PA KEY
X1
DATA1
DATA7
+25V
+25V
+25V
-15V
+7.5V
+7.5V
DATA0
DATA6
-15V
DATA5
DATA3
X8
DATA4
DATA2
X11
1
9
9
7
2
7
8
5
3
8
24V DC
11
11
18
17
18
10
17
10
15
15
13
13
16
16
19
12
19
12
14
14
20
20
TU-CU BUS X1 X1
1 Shield GND 1 GND 1
2 GND RX AF 2 RX AF 2
3 +24V TX AF 3 TX AF 3
4 CAN_Vcc AGC 4 AGC 4
5 CAN_H MGC/ALC 5 MGC/ALC 5
6 CAN_L DSC RX AF 6 DSC RX AF 6 X1
7 CAN_GND DSC WR AF 7 7 7 DSC WR AF
8 Supply_ON SUPPLY OFF 8 8 8
9 Audio_IN+ SUPPLY ON 9 9 9
10 Audio_IN- BATINFO 10 10 10
11 Audio_OUT+ +25V 11 11 11

12 Audio_OUT- +25V 12 12 12
+25V 13 13 13
-15V 14 -15V 14 14
-15V 15 -15V 15 15 -15V
CONTROL/INTERCON +15V 16 RX/EX SIGNAL PATH +15V 16 16 +15V
SYNTH. AND DSC WR
AUX +15V 17 +15V 17 17 +15V
1 NMEA_IN+ 18 +7.5V 18 18 +7.5V
+7.5V 19
60-122880 60-131332
2 19 19
NMEA_IN-
60-127961 +7.5V +7.5V +7.5V
3 GND 20 GND 20 20
GND GND
4 LINE_OUT
5 LINE_IN
6
W1 W1
TX_INHIBIT
7 TX_KEYED
8 X2 X2 X2
12V_OUT GND 1 GND 1 1 GND
9 EXT KEY 2 2 2
10 ADR0 ADR0 ADR0
GND ADR1 3 ADR1 3 3 ADR1
ADR2 4 ADR2 4 4 ADR2
ADR3 5 ADR3 5 5 ADR3
DATA0 6 DATA0 6 6 DATA0
SUPPLY DATA5 11 DATA5 11 11 DATA5
ALARM 13 13 13
1 AC_ALR DATA7 DATA7 DATA7
2 STROBE 14 STROBE 14 14 STROBE
GND 15 15 15
3 VBAT- GND GND GND
4 PA KEY 16 16 16
VBAT+ 17 17 17
5 NC PA TEMP
18 18 18
PA PROTEC 19 19 19
FILPEAK 20 20 20
GND GND GND
TX/RX W2 W2
TX/RX EX SIGNAL X11 W11
3.12 Transceiver unit interconnection diagram
TX SIGNAL 1. LO X12 W12 X12 1. LO

2. LO X13 W13 X13 2. LO
RX SIGNAL X9 W9 X9 RX SIGNAL 3. LO X14 W14 X14 3. LO
X9 RX SIGNAL X8 RX TELEX
X5 DSC RX
3-7
W16
DSC RX
DSC RX W10
99-130954-A
500 W
X1 1
NC
SUPPLY OFF 2
SUPPLY ON 3
BAT INFO 4
+24V 5
SMPS +24V
+24V
6
7
8
60-126172
-15V
-15V 9
+15V 10
+15V 11
+7.5V 12
+7.5V 13
GND 14
Relay
AUX- 1-15
AUX+
+BAT
X7
X6
+7.5V 18
+7.5V 17
+7.5V 16
+30V
+15V 20
+15V 19
GND
GND
1-15
19
16
18
17
20
W7 W6
1-15
1-15 AUX+
19
16
19 GND
16 +BAT
18
17
18 +30V
17 Relay
20
20 GND
PA AND FILTERS 60-125886

+7.5V
+7.5V
+7.5V
+15V
+15V
AUX-
X6
X3 X3
X7
GND 1 1 GND
+7.5 V 2 2 +7.5 V
+7.5 V 3 3 +7.5 V
+7.5 V 4 4 +7.5 V
+15 V 5 5 +15 V
+15 V 6 6 +15 V
+15 V 7 7 +15 V
GND 8 8 GND
GND 9 9 GND
SMPS
Temp NTC 10 10 Temp NTC
HTON 11 11 HTON
Telex 12 12 Telex
60-126136 Sense + 13 13 Sense +

Sense - 14 14 Sense -
X4 W3 X4
DC+ 1-20 1-20 PA+
X5 W4 X5
DC- 1-19 1-19 PA -
DC+ 20 20 PA +
EX SIGNAL
SUPPLY OFF
W5
PA PROTEC
SUPPLY ON
24V DC
PA TEMP
BATINFO
FILPEAK
STROBE
PA KEY
DATA7
DATA6
DATA1
DATA5
DATA4
DATA3
DATA0
DATA2
+ X8
ADR2
ADR0
ADR3
ADR1
+7.5V
+7.5V
+25V
+25V
+25V
+15V
+15V
GND
GND
GND
GND
X2
-15V
X8
-15V
X11
TX SIGNAL
X1
- 1
14
14
19
16
19
15
13
12
16
15
13
12
18
17
10
18
17
10
11
11
9
20
20
7
8
8
4
X1 X1
GND 1 GND 1
RX AF 2 RX AF 2
TX AF 3 TX AF 3
AGC 4 AGC 4
MGC/ALC 5 MGC/ALC 5
DSC RX AF 6 DSC RX AF 6 X1
TU-CU BUS DSC WR AF 7 7 7 DSC WR AF
1 SHIELD SUPPLY OFF 8 8 8
2 GND+ SUPPLY ON 9 9 9
3 +24V- BATINFO 10 10 10
4 CAN_Vcc 11 11 11
SYNTH. AND
+25V
5
6
7
CAN_H
CAN_L CONTROL/ +25V
+25V
12
13
14
RX/EX 12
13
14
12
13
14
DSC WR
-15V
INTERCON SIGNAL PATH
CAN_GND -15V
8 SUPPLY ON -15V 15 -15V 15 15 -15V
9 AUDIO_IN+ +15V 16 +15V 16 16 +15V
60-127961 60-122879
10 17 17 17
60-122880
AUDIO_IN- +15V +15V +15V
11 AUDIO_OUT+ 18 +7.5V 18 18 +7.5V
12 +7.5V 19
AUDIO_OUT- +7.5V 19 19 +7.5V
+7.5V 20 GND 20 20 GND
GND
AUX W1 W1
1 NMEA_IN+
2 NMEA_IN- X2 X2 X2
3 GND GND 1 GND 1 1 GND
4 ADR0 2 ADR0 2 2 ADR0
LINE OUT
LINE IN 4
6 TX INHIBIT ADR2 4 ADR2 4 ADR2
TX KEYED 6
8 +12V DATA0 6 DATA0 6 DATA0
9 DATA1 7 DATA1 7 7 DATA1
EXT KEY
10 DATA2 8 DATA2 8 8 DATA2
GND
SUPPLY DATA5 11
12
DATA5 11
12
11
12
DATA5
ALARM DATA6
13
DATA6
13 13
DATA6
1 AC ALR DATA7 DATA7 DATA7
2 STROBE 14 STROBE 14 14 STROBE
GND 15 15 15
3 VBAT- GND GND GND
4 PA KEY 16 16 16
VBAT+ 17 17 17
5 NC PA TEMP
18 18 18
PA PROTEC 19 19 19
FILPEAK 20 20 20
GND GND GND
W2 W2
EX SIGNAL X11 W11
TX/RX TX SIGNAL 1. LO X12 W12 X12 1. LO
TX/RX 2. LO X13 W13 X13 2. LO
RX SIGNAL X9 W9 X9 RX SIGNAL 3. LO X14 W14 X14 3. LO
X9 RX SIGNAL X8 RX TELEX
X5 DSC RX
W16
DSC RX
DSC RX W10
99-133446

Antenna Tuning Unit
3.13 Antenna Tuning Unit

3.13.1 ATU module 60-122883 (150 W/250 W)
The ATU module comprises tuning network, measuring system and micro-controller circuits. The ATU
module matches the impedance of the antenna to 50 ohm in order to gain the best possible SWR. The
ATU module communicates tuning process and frequency information with the transceiver unit. The
tuning network consists of capacitor bank 1, capacitor bank 2, and an inductor bank. With these it is
possible to form either an L-network or a p-network. The capacitor banks and inductor bank are built up
by binary related capacitors respectively binary related coils. The setting of capacitance and inductance
is accomplished by relays. A current detector at the antenna output terminal is used for measuring the
antenna current for display at the Control Unit. To prevent overload of the relays, current detectors are
incorporated in the inductor bank and in capacitor bank 2 and information fed back to the transceiver
unit to decrease the output power if maximum permissible current is exceeded. To prevent overheating
a temperature sensor is incorporated which at excessive temperatures commands the transceiver to
reduce the output power.
In receive mode an RX-Amplifier included in the Antenna Tuning Unit is utilized, to improve the sensitivity
of the system by providing 50 ohm impedance.
Block diagram
DC regulators
12V 5V
regulator regulator
to digital RX amplifier
circuits
Rx
13/24V 24V in Rx & Tune Tx Amp
SMPS 13V in Tx
24V
control by
to relays uP to relays
RF filter
Antenna
RX/TX/ Tuning circuit

ATU/COM High Pass Filter rx L-bank L-bank
24V DC Directional IL detector
Tune Att. tx Iant. detector
Coupler
4 dB
26dB Antenna
Modem filter Ic Connector
detector Horn
CB1
control by
uP
CB2
Vref Vw
control control current

Demodulator Modulator Rx/Tx banks detectors
Phase &
Voltage
Temperature
Detectors Micro Prosessor
sensor
40637

Antenna Tuning Unit
3.13.2 ATU module 60-131020 (500W)

The ATU module comprises tuning network, measuring system and micro-controller circuits. The ATU
module matches the impedance of the antenna to 50 ohm in order to gain the best possible SWR. The
ATU module communicates tuning process and frequency information with the transceiver unit. The
tuning network consists of Capacitor Bank 1, Capacitor Bank 2, and an Inductor Bank. With these it is
possible to form either an L-network or a p-network. The capacitor banks and inductor bank are built up
by binary related capacitors respectively binary related coils. The setting of capacitance and inductance
is accomplished by relays. A current detector at the antenna output terminal is used for measuring the
antenna current for display at the Control Unit. To prevent overload of the relays, current detectors are
incorporated in the Inductor Bank and in Capacitor Bank 2 and information fed back to the transceiver
unit to decrease the output power if maximum permissible current is exceeded. To prevent overheating
a temperature sensor is incorporated which at excessive temperatures commands the transceiver to
reduce the output power.
Block diagram
DC regulators
12V 5V
regulator regulator
to digital
circuits
Fan
Temperature
controlled
24V
to relays
RF filter
Antenna
RX/TX/ Tuning circuit

ATU/COM High Pass Filter L-bank L-bank
24V DC IL detector
Directional Iant. detector
Tune Att.
Coupler
6 dB
31dB Antenna
Modem filter Ic Connector
detector Horn
CB1
control by
uP
CB2
Vref Vw
control current
Demodulator Modulator banks detectors
Phase &
Voltage
Temperature
Detectors Micro Prosessor
sensor
99-126349

Power control and protection system
3.14 Power control and protection system

The Transceiver has an automatic power level system, which ensures that optimum power is delivered
to the Antenna. The Tune Sequence, which is automatically initiated when keying the transmitter after
a frequency change, makes the Tuning Network of the Antenna Tuning Unit tune to the best obtaina-
ble SWR. This is followed by an Automatic Level Control (ALC) adjustment according to the available
power supply voltage, measuring the output current of the PA Filters (FILPEAK @ 10 Vp at full output),
transmitting AM carrier, and setting the overall gain by the ALC voltage (MGC/ALC). It is now possible
to transmit on full output power unless protection is activated or LOW POWER is selected. The output
power is continuously monitored by the microprocessor, and is automatically adjusted during transmis-
sion to provide reliable communication.
3.14.1 Power Amplifier Protection

The protection of the power amplifier consists of V+I protection, SWR protection, and thermal protec-
tion. When PA PEAK, the output signal of the voltage detector at the output of the power amplifier is
exceeding 10 V the output power is reduced to a safe level. If the ALC loop is at fault, disconnected or
responding too slow and the PA PEAK is exceeding 10V, the gain will be reduced in the power amplifier,
operating as a local and independent PA protection. The thermal protection consist of a temperature
sensor on the power amplifier and an average detector on the Control/Intercon module reducing the
output power when the duty cycle of the transmitted signal exceeds 50% for more than 60 seconds. The
available power supply voltage is measured in the DC power supply and the information is transferred
to the Control/Intercon module. If the supply voltage is dropping the microprocessor will adjust the
output power to keep distortion below the limits.
3.14.2 Antenna Tuning Unit Protection

The ATU is protected by several detectors all monitored by the ATU´s microprocessor, which calculates
the SWR, temperature, maximum voltage and current. If these parameters are not below safe operating
limits it requests for lower power.

3-12
RX SIGNAL
Block diagram
RX/EX SIGNAL PATH 60-122880 PA AND FILTERS 60-122881 CONTROL/INTERCON 60-127961 ATU MODULE 60-122883
24V DC 24V DC
TU-ATU
Coax SWR Current Current
EX SIGNAL SWR TX SIGNAL
Det. LP Filters Det. Det. Det.
Current
Det.
Power control and protection system
Temp. V+I Det. PA peak Protect. Peak Det.

Sens. Det. Det.
TU-ATU TU-ATU
Com Com
Modulator Demodulator
PA TEMP PA PROTEC FILPEAK

ATU-TU ATU-TU CPU Temp.
Com Sens.
Demodulator Modulator
MGC/ALC
Average Det.
CPU
Comparator
SMPS 60-122882 D/A DSP

Converter
Peak Det.
Power BATINFO A/D

Supply Converter

Det.
99-133506
98-130890-D
Chapter 4
Service
4.1 Preventive maintenance
Due to the modern design of the transceiver preventive maintenance can be reduced to a minimum pro-
vided the equipment is correctly installed. To ensure maximum performance and minimum repair trouble
we recommend you to follow the below stated headlines for preventive maintenance.
1. The condition of the battery should be checked at frequent intervals. The battery must always be fully
charged and should be topped up frequently with distilled water (liquid should be 5 to 10 mm above
the plates).
2. Check the condition of antenna installation, ground connection and cables at regular intervals.
3. Keep antenna feed-through insulators clean and dry.
4. Ensure that no objects are obstructing the free airflow through the cooling channels of the Transceiver
Unit and keep the units free of dust accumulation to prevent overheating.
5. For cleaning use a damp cloth. Sticky dirt may be removed using a cloth with a weak soap solution.
Wipe off with a clean cloth.
4.2 Cleaning the Air filter (500 W Transciver only)
Service
The transceiver unit uses 2 fans to cool all circuitry inside the unit. To keep the cooling air clean an air
filter is placed in front of each fan. These air filters should be cleaned frequently, especially under dusty
working conditions. A dusty air filter will block efficient cooling and the transmitter output power is hence
reduced to avoid over-heating.
Remove the air filter cover from the buttom of the transceiver unit by gently pushing towards right and
then pulling it out from the cabinet. Take out the air filters from the cover. Clean the air filters refit and
re-assemble the unit.
Air filter
Filter cover
99-126839
98-130890-D Chapter 4: Service 4-1

Software update
4.3 System test and verification

Ref to ‘User Manual’ – chapter 'Service & Preventive Maintenance'
4.4 Software update

For Software upload please refer to 'SAILOR 622286248/6249 VHF and MF/HF Service tool Manual' -
98-133342 available for download at www.cobham/satcom.
Latest SW for CU and TU is available for download at www.cobham/satcom.
Software version1.06 or higher in TGZ files is uploaded using the Radio Service Tool, software version
1.06 or higher in TIIF files is uploaded using the TMA tool version 1.04 or higher.
4-2 Chapter 4: Service 98-130890-D

Chapter 5
Spare part exchange

5.1 Disassembling the Transeciver Init (150 W/250 W)
To open the transceiver unit loosen the 4 screws (2 on each side) on the side of the cabinet.
Move the screws to the side to unlock the TU. Now open the TU by pulling the front door towards you.
Loosen 4 screws

Screw A2 M6x30mm
87.838
Hinge Bolt, Hinge Bolt,

ø11.4 x 27mm ø11.4 x ø27 x 54.5mm
238107 238106
Spare part exchange
98-130890-D Chapter 5: Spare part exchange 5-1

Disassembling the Transceiver Unit (500 W)
5.2 Disassembling the Transceiver Unit (500 W)

To remove the transceiver cover loosen the 4 screws (2 on each side) on the side of the cabinet and
pull the cover from the transceiver.
Loosen 4 screws
M6x16
SMPS modules
Loosen 17 screws
M3x8
99-126728
To open the transceiver loosen the 2 screews on the right hand side of the cabinet.
Loosen 2 screws M6x30

Required service tool:
hexagonal socket wrench,
bits 1/4", length min. 16 cm.
SYNTHESIZER and
DSC WR module
RX/EX SIGNAL
PATH module
CONTROL/
INTERCON module
99-126886
5-2 Chapter 5: Spare part exchange 98-130890-D

Shielding plate, only for FCC
98-130890-D
H2 H1
C53
C52
PA AND FILTERS 60-122881/60-123937 SYNTHESIZER AND
C244
C227 E3
C145
C241
DSC WR 60-122879
C228
H17 H15 W10
C229
C208
R180 R180
W16
C138
R122
R123
R124
R125
R126
K13
W14
C3
M0. ADJ
R150
K1
2 DSC RX RX TELEX
L43
K14 X1
C126
C235
V3
C90
3.LO
R171
R172
C233
C245
C252
C164 C139
R168
R167
R142
R135
R133
H35
L12
C75 C221 C209
C108
C144
C206
C11
X100
C65
H32
C50
C31
C256 H33
C150
C140
L57
L40
C127
C80
C98
L52
C151
C153
C152
N6
L32 N16
C213
C26
H25
R189 H13
C32
C141
R141
X2
C72
C92 C137 C219
L46 C198
C205 C220 D3 C197
C106
C68 L55 C196
R82
R173
C199
C73
C89 C188
L44
C189
C143
C81 H18
C154
C190
L11
C96 C67 C191
C88 C192
C248
C250 C63 C193
X2
H46 C97 C69 C194
C136 N3 C195
R179
C200
C128
C76
L31
C77
C54
V47
R83
C133 R85
C207
C181
C186 R84
V49 C240
L13
R2
L30
C64
R29
C57
C66
L41
L56
C187 C132 V50
C93
C212
L21
L51
R1
C86 C130
L54
C78 L45
R81
R79
R77
R143
R144
R145
R146
R147
150 W/250 W Transceiver Unit
C135 C134
L22 H45
R163
C211
C129 X8 C226
X8 R162
C247
C87
C204
C79 R153 R148
R152 R149
C71 C131 D4 1 1
R151
C94 L42 R31
H23 C70 H11 H16 C155
C61
C85
K3 C84
L53
C148
R106
R105
R104
R103
R97
K10
C62
D1
C210
K8
R111
R110
R109
R108
R107
W13
C251
K11
R177
R114
R113
R112
R116
R115
L50
R187
R188
R197
K16
K15
W12
C246 R176
R186 C243 R169
2. LO
K9 C147 1.LO
R132
V25
V24
V23
V22
N15
C162
R131
RX/EX SIGNAL
C20
C161 C163
C146 C185 C184 R130
C149
X7
R174 C160
R161
C159
R36
C118
C115
C46
C225 R129
C112
C110
H6
C48
V15
H21
C12
PATH 60-122880
C34
C158
N7
L16
R212 R128
C230
L14
C254
H19 L1
R54
R12
N25
C10
R209
R203
R202
C157
R194
C120
R127
L8
R63
C122
R195
C123
1 1
V71
V70
C95
C231
V31
R211
V33 R164
V60
C255 R192
R210 R182
H47 R213 H10 H14
C18 R191
C27
C17
V7 V5 C124
C28 R51
R160 R102
V59
C105 R50
R181
C16 C215 R13 C38
C37 R23
H27 C29 X16
C103 R8
V11
R165
H48
C40
R101
C23
C5
R52
C24 C102
R17 C4 R11 X11
R22 R10
C176 R37 C169 R42
T3
R9
R16
R15
R7
C175
V10
H42 H43
W8
C253
R154
C6
C180
C43
C42
C41
C182 H24 X11
C166
C142
C167
C39
C173 C172 C242
C249
H41 H44
C183 C7
C14
C44
H22
T1 R6
R18
V9
R38
T2 C25
R43
X17
R21
The following modules are available as service parts.
H49 C15
C22
TX W9
R26
V17
R19
R20
C30
H26
W11
V12
C35 C9 R5 R25
V8
C13 C214 C100 R55
R24
C36 C156 V43
V16
C104 R27 C101 R53 C8
R49 C174
RX
C177 R46 C201 C202
R219
H9 R216 H12
EX
V14
R218
C47
C238
V6 V4 V28
V32
C114
C33
R178
C125
R196
R178
R64
R217 C234
C119
C178
R193
R62
L9
R190
L15 R155
R14
R66
C232
R86
R4
R3
R175
R134
C171
C224
C1 H7 R185 C239 C237 C236 R95
R220 N24 R184 R80
C45
C121
C49
C117
C168
R94
C111
C107
C109
C203
R215
V2
C218
V48 V51 V52 C99
C223 C222 R63
C217
N1
R35
R138
R214
R59 R156 R157 N2
W1 W2
N14
R183
N4
R159
C216
C2 R158
R96
C179
R98
H5
R90
C165
R39
R41
R45
R48
R68
R73
R58
R61
R99
R198
R200
R136
R204
R206
R208
C170 R74
R70
R71
V55
R88 V30 R75
V46
C59
R56
V13
C19
R69
N17 N18 N19 N20 N21 N22 N23 R140 V53
N13 N5 N8 N9 N10 N11 N12 N27
R166
R91 V44
C21
R89 C113
V45
R137
V18
V19
V20
V21
V37
R139
R34 R40 R44 R47 R67 R72 R57
R93 R100 R199 R201 R205 R207 R65 V42
Chapter 5: Spare part exchange

R60
R92
R32
E1
V27
R28
R30
R33 H29
V26
H8 H31
H20
X3 V35 R170 V40
1 V36 V34 H28
1 X4 H30
1 X5
X3 X4 X5
E2
H37
H4
W3 W4 W5
CONTROL/INTERCON. 60-127961
1 SMPS 60-122882 1 1
5.3 Transceiver Unit module location
1 1
W6
W7
W15
- +
24 V DC TU-CU BUS AUX SUPPLY DSC RX RX/TX

99-133526 ALARM
5-3
Transceiver Unit module location
Spare part exchange

500 W Transciver Unit
The modules and internal cables illustrated in the following pages are available as spare parts, some as
individual parts and others as part of a subassembly or a set. For identification of parts and part numbers
refer to the eShop at the Thrane & Thrane Extranet.”
R5 V4 R2
H2 H3
H4
R79 R3
R21
R73 C68 C5
V33
V19
V37 C1
W19
C53 R57 R78 V17 R68 R70
C6
C57
V6
C7
R69 V5 C2
R10
R27
R76
C44
V38
C47
R64 R23
X1
C56 R18 R56 R19

R4 V25
C66
V16
V22
R28
R29
R33
R45
V14
R32
R7
V34 R74 R82
V24 N5 N2 V29
C3
R67
V11
R63
C54
H1
V47
C67 R31
N3
R51
C38 R75
R17
V36 R14
V15
V18
HS2 R72 C8 R8 C4
V26 R34 R50 R13 R84
V23
R77 R54 R62 V12
R55 R15
C55 R12 R30 R6
V46
R9
R39
R71
V28
R66
R81
C65
V21 R20
N1
R36
R65 R46 C58 V32 R1
D1
C62
R16
R26
R41
C45
R11
V44
V42
C40 L4 C39 C49
C61 R53 V27
R80 V31
V1
R24
R83
C46
C52 V30
C31 N4
V40
C9
R52 R40
R59 C18
R25 C51 C17 C15
R22
V8
L1
V7
C30 C29
R60
C43
T1 C11
T2
R42
C42 C14 C12
C34 L5 HS1
C33 C32
V9
R86 V20 C60 C16 C10
L2
R61
C13
V2
R44 R58
C63
C37 R47
R43
V43
V45
L3 C59
C36 C35 R35 R48
C71
C64
V51 R38
C41
V52
V50
R37 H10 H11
C19 R87 V49

C20 L6 V48 R49 V41
C69
V10 V39 R85

V35
SMPS 60-126172
H9 H12
H8
X7 X6
C70
W17 W18
H5
H7 H6
X7
C74
X6
H3 H4
SMPS 60-126136 H5
W20
R74
R73
R55
X3
R49 R48
V25
V34
C31
R63 R62
R70
C101 C102 C103 C104 R30
R1
R35 C44 R29

R69
N4
R71 R26
R54
V13
C26
V37
C24
L8 C18
R42
R31
R27 C5
V24
R32
N2
V35
R46
C7
R21 R40
C19
C105 C106 C107
C38
H2 C108 R66 R28
N5
C20
R43
V20
C15 C39 R68 R67
N1
C12 C37 R15 C54 R11
R44 R37
R22
R41
C14
R39
C11
R36
V4
R4
C1
C9
C109 C110 C111 C112 V16 V18

R53 R56
R82 R79
R57 R65
R80 R81
L10
R51
V31
H10 L4
V32
V28
L11 H9
C121
C13
L9
R50
C23
R58
C6
C75
R52 V33
V30
C56
C47
C76 C78 C77
H13 V36
C16 H12
C32
C122 L6 V38 V39 C25
H34 H39
H35 H40
W21
H36 H41
K2
H37 H42
K1
H23 H28
H22 H27 H38 H43
C63
X4
H21 H26
V22
V21
H20 H25
H19 H24
C29
C123 R76 L12 C60
R33
C21
C64
C66
T1
C65
C72
R77
C58
L14
C48
C124 C59
L5
C70
L1
L3 R75
W22
C30
C28
R78
C55
X5
L13 C61
C129 R61 H18

H17
H33
H32
H16 H31
C71
H15
H14
H30
H29
C22
H44 H49
H45 H50
L2 H46 H51 C27

V8 V12 H47 H52
L7
H48 H53
C57
V14
C62
V15
V7 R24
C131
R25 V6 H11
C17
V11
R34
R23
C3
H1 C132 C130 V5
C68
C69 C67
R9 V10
R13
X10 X11 X12 X13 V2
C4
R19
OLS
R16
R83
R17
V19
R84
V3 N3 C2
R85 R3
R86 R2 R18 R12
H6
R14 R10
X22 V1 V17
R7
R6 R8
V9 R5 X23 H7
H8
C8
W23
99-126732
Loosen 15 screws M3x8

to remove SMPS chassis
Internal SMPS
PA SMPS
99-126896

98-130890-D
SYNTHESIZER AND
DSC WR 60-122879
W10 W16
M0. ADJ W14
DSC RX RX TELEX 3.LO
1 1
W13 W12
RX/EX SIGNAL 2. LO 1.LO
PATH 60-122880
1 1
W11 W9
EX RX
W1 W2
W8
Chapter 5: Spare part exchange

TX
CONTROL/INTERCON.
60-127961
1 1
W7 W6
W15
- +
99-133641 TU-CU BUS AUX SUPPLY DSC RX RX/TX
ALARM
24 V DC
5-5
Spare part exchange

Module overview
5.4 Module overview

Control / Intercon. module 60-127961
R429 R430
CR10
R296
C239 R283
R302
C312
R178
C231
R289
R515
Q19
Q25
C269
R316
R354
REF
Q26
R297
W12
CR5
R266
C242
R371
U58
C383
C214
C219
R432
R431
R291
C375
C262
C220 C268 R184
C221
CR25
C205
R186
R130
C30 C387 R508
Y11
U39
R288
C280
R323 C409
U56
R392 R493 R132
R492
R347 R185
CR6
R309
C281
R320 R124
R541
R294
U60
C226
U17
C66
U33
C101
R180
R21 R467 C320
R321 R554
C103
R503
R287 C290 R518
L6
U59
R433 R516
R322
R293 CR21 C288 R361 R362
U5 U6 R434 R182
C31
C376
R519
C139
R543
C289
C388
R179
C241
R363 R364
C140
C223 R315 CR23 R544 R183 R181
R277
CR22
C236 R551
CR13
C206 R357 R545 R174 CR3 CR4
R177
R400
R168
R307
Q18
C326
R306
R387 R388
R393
CR17
C265
R591 R553
Y7
R128
C227
C264
R350 C275 R349 CR8
R169
R17
R162
R18 J7
C215
U32 J8
C208
R164
C138
C137
R345
C100
C278 R348 R605 R396
CR9
C325
R550
R165
R163
C282
R355 C284
U44 R383
R123
R129
C285
U40
R499
C99
R546 R629
C229 U35
R159
R295
C270
R314
L5
R346
R502
R512
R379
C266
C442
U57
C263 R500
L4
CR14 R547 R498
U16
CR7
C274
C218
CR2
C382
R581
R282
CR15 R343 R582

CR19
R548
R549
R311
C419
U61
C418
R360
R298
C267 C420
CR16
R271 R584 R122 C93 C98 R121

R353 R344 R542
R280
C97
R268
R583 R119 R127 R120
C134
C124
C135
C129
C128
C133
C127
C132
C126
C125
C130
C131
C237 R619
C276
C122
C120
C108
C109
C121
C119
C118
C116
R358
C117
C110
C216
C112
C113
R352
C111
R580 C95
C107
C106
C105
C114
C115
C213 R532
R125
R604
C279 R351 R560
R600
R303 R517
R144
R151
R150
R145
R149
R148
R147
R152
R146
R143
R142
C283
R141
R422 C96
R276
C286
R476
R478
C437
R482
R614
R477
R175
R170
U64
R171
R284
R356 R412
R274
R304
R319
C438
R564
R602
R603
C287 C60
C212
R424 R441
U41
R626 R481
C235 R466
CR20
TP*
R439
R438
R66 C408
C435
R410
TP136
C273 C271 R566 C75

R262
R613 R483
C436
C405
C56
R568 R74
C72 C86
R73
C62
C68
R313
C65
R620
R275 R305 C272 CR27
C61
C57
R402
R615
R68
R176
R98
R449
R448
R442
R440
R403
R436
R437
C79
R407
R406
R621
U12
R281
R92
C90
C94
R64
R72
R601
C404
R117
R579 U52
C433
R443
U13
C87
C91
C234
U63 W5 CR26
C391
TP265
TP* TP264
R108
TP*
C434
R109
R596
R578
C53
TP267
TP*
C413
R599
C415 C416
C228
C414
R527
TP262
TP*
C431
TP443
TP* TP266
TP*
L3 R446
TP263
TP*
C432
TP261
TP*
Y12
C207
U34 R411
C401
U31
Y13 U48 C369
R606
C399
R612
R610
C64 R33 R445
R425
C211
R408 R62
R609
R586
R607
C400
U11
R611
C63
U50
C363
R405 R423 C47 R61 C35 R37 C32 C52 R45
TP260
TP*
C361
R447
R484
R485
C44
U14
C370
R479
R480
R404
C54
R608
R58
R616
R46
R617
R409 R444
C36
R35
R308
C39
R40
R49
R39
C410
R490
R273 R301
R126
R140
C398
C406
R528
U7
U9
R278
R60
R50
R55
D3
C402
C411
R594
C429
C428
C50
U62
C49
R67
C430
R592
R593
R47
C233
R286
R300
C427
R318
C209 R187
R69
C210
R272
R531
C67
C364
C84
C217 R458 R71
C403
C149 R78 R77
R100
C83
C80
C232 C238 C368 C151 R627
C85
C200
C222
R457 C77
U20
U18
R285 R317 C141 Q8
Y4
U65
U19
R628
R450
C240
U51
U15
C152
D1 U8
C38
R451 R456
R312
U22
R106
C143
R195
R279
R452 R455 R203
C76
L2
C230
N4
R242
R453 R202 R112
VR2 CR11
Q20
R454
R241
R210
R618
R75
R207
R244
U27
R188 R38 C46
R110 C89 C37
CR18
R194
R189
C156
+
R246
RV1
C148
C225
C366
C142
C147
R248
R249
C150
R44
R42
R36
R32
C194
C193
R290 R139
C195
C123 C102 C104
C88
R507
C153
R221 C51 C92 R131
R299
C196
R53
R191 R192
C81
R56
R57
C78
VR1
C145
R206
C55
R54
C144
R310
E1
C171
R292 C224 U24
C58
C41
R190 R193 R43 R31
D4
C43
R243
R113
C189
C188
C187
U10
R111
R227
R217
R211
R41
R101
R105
R205
R103
C42
R99
C146
C45
C33
C202
C154
R204
CR12
R245
R263
C198
C203
R270
R209 R208 C158

Q24
C365 C157
K1
R267
R264
C204
+
R254 VR4 R265
C201 C197
C199
R252 R34
U30
C164
C183
C163
C165
C162
C160
C159
C161
C180
C178
C177
C175 C179
J11 C40
R255
Q22
C186
C190
R247 J3 J15 J4
F1 R261
C192
R251 R260
R258
U29
Q21
R256
R250
C191
R253
R259
Q23
R257
Synthesizer and DSC WR module 60-122879
RX/EX Signal path module 60-122880

Module overview
PA and filters module 60-122881 (150 W/250 W)
PA and filters module 60-123937 (FCC)
Spare part exchange

Module overview
PA and filters module 60-125886 (500 W)
SMPS module 60-122882 (150 W/250 W)
SMPS module 60-126172 (500 W)

Module overview
SMPS module 60-126136 (500 W)
Spare part exchange

Accessory list
5.5 Required service tools

150 W/250 W
For disassembling transceiver unit: Slotted screwdriver
For shield cover, print and cables: Torx screwdriver T10
500 W
For disassembling transceiver unit: Hexagonal socket wrench 1/4" lenght min.16 cm
For transceiver modules and cables: Torx screwdriver T10
Slottet screwdriver
Spanner for M5 nut
5.6 Accessory list

Item Part no.
SAILOR 6301 Control Unit Class A 406301A
SAILOR 6302 Control Unit Class E 406302A
SAILOR 6360 150 W MF/HF Transceiver Unit DSC Class A 406360A
SAILOR 6361 150 W MF/HF Transceiver Unit DSC Class A FCC 406361A
SAILOR 6362 150 W MF/HF Transceiver Unit DSC Class E 406362A
SAILOR 6381 150 W/250 W Antenna Tuning Unit DSC Class A 406381A
SAILOR 6382 150 W/250 W Antenna Tuning Unit DSC Class E 406382A
SAILOR 6383 500 W Antenna Tuning Unit DSC Class A 406383A
SAILOR 6006 Massage Terminal 406006A
SAILOR 6001 Keyboard for Message Terminal 406001A
SAILOR 6103 Multi Alarm Panel 406103A
SAILOR 6080 Power Supply 406080A
SAILOR 6081 Power Supply & Charger 406081A
SAILOR 5083 Power Supplu & Charger 405083A
SAILOR 6197 Ethernet Switch 406197A
SAILOR 6208 Control Unit Connection Box 406208A
SAILOR 6209 Accessory Connection Box 406209A
SAILOR 6270 External 8W Loudspeaker 406270A
Optional installation kit (3 x SAILOR 6080 + 1 x SAILOR 6081) 406081-004
ATU Mounting Kit

Mounting plate and fittings for mast 737589
Mounting plate 737588
Gasket kit for Antenna Tuning Unit 737822

Glossary
Chapter 1: General information
AGC Automatic Gain Control
ALC Automatic Level Control
AM Amplitude Modulation
ATU Antenna Tuning Unit
CU Control Unit
CW Continuous Wave (modulation, used for morse communication)
DSC Digital Selective Call
FEC Forward Error Correction (Broadcast)
HF High Frequency
J
J2B DSC/Telex (modulation)
J3E SSB Telephony (modulation)
LSB Lower Side Band

Glossary
MF Medium Frequency
MID Maritime Identification Digits
MMSI Maritime Mobile Service Identity
MSI Maritime Safety Information’s
98-130890-D Glossary-1
Grossary
NMEA National Marine Electronics Association
PA Power Amplifier
PTT Push To Talk
RTTY Radioteletype (Radio Telex)
RX Receive(r)
S
Sitor SImplex Teletype Over Radio (Radio Telex)
SMPS Switch Mode Power Supply
SSB Single Side Band
TU Transmitter Unit
TX Transmit(ter)
USB Upper Side Band

Glossary-2 98-130890-D
98-130890-D
www.cobham.com/satcom

SAILOR 6300MFHF Installation Manual 4

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SAILOR 6300MFHF Installation Manual 4

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SAILOR 6300 MF/HF DSC

SAILOR 6300 MF/HF DSC

Document number: 98-130890-D

© 2013 Thrane & Thrane A/S. All rights reserved.

• SAILOR is a registered trademarks of Thrane & Thrane A/S.

GROUND THE EQUIPMENT

DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE

Do not operate the equipment in the presence of flammable gases or fumes.

KEEP AWAY FROM LIVE CIRCUITS

radio is transmitting. High voltage which can cause death or serious

250W MF/HF with 6 ch. Scanning SAILOR 608x

Training information (for FCC approved equipment)

• Never touch the antenna when transmitting

• Use only authorized T&T accessories.

Chapter 1 General information

1.1 Introduction ..............................................................................................................................1-1

1.2 Technical data............................................................................................................................1-1

2.2 Mounting the units..................................................................................................................2-1

2.3 Ground connections ..............................................................................................................2-8

2.4 Grounding considerations ..................................................................................................2-9

2.6 DC Power cabling ....................................................................................................................2-17

2.8 Position and time information...........................................................................................2-24

2.9 Telex operation.........................................................................................................................2-25

2.11 Programming Telex ID ..........................................................................................................2-29

2.12 Configuration ............................................................................................................................2-31

2.13 Final installation check..........................................................................................................2-35

Chapter 3 Technical description

3.1 Control Unit................................................................................................................................3-1

3.2 Transceiver Unit........................................................................................................................3-1

3.3 Control/Intercon module 60-127961...........................................................................3-1

3.4 Synth. and DSC WR module 60-131332 .....................................................................3-1

3.5 RX/EX signal path module 60-122880...........................................................................3-2

3.6 PA and Filters module 60-122881..................................................................................3-2

3.7 PA and Filters module 60-123937 (FCC) ....................................................................3-3

3.8 SMPS module 60-122882 (150 W/250 W)................................................................3-3

3.9 SMPS module 60-126172 (500 W)................................................................................3-3

3.10 SMPS module 60-126236 (500 W)................................................................................3-4

3.11 Transceiver unit block diagram .........................................................................................3-5

3.12 Transceiver unit interconnection diagram...................................................................3-7

3.13 Antenna Tuning Unit .............................................................................................................3-9

3.14 Power control and protection system............................................................................3-11

4.1 Preventive maintenance ......................................................................................................4-1

4.2 Cleaning the Air filter (500 W Transceiver only).......................................................4-1

4.3 System test and verification...............................................................................................4-2

4.3 Software update.......................................................................................................................4-2

Chapter 5 Spare part exchange

5.1 Disassembling the Transceiver Unit (150 W/250 W).............................................5-1

5.2 Disassembling the Transceiver Unit (500 W).............................................................5-2

5.3 Transceiver Unit module location....................................................................................5-3

5.4 Module overview......................................................................................................................5-6

5.5 Required service tools............................................................................................................5-10

5.6 Accessory list.............................................................................................................................5-10

Glossary .................................................................................................................... Glossary-1

1.2 Technical data

Frequency range: Refer to sections concerning specific characteristics

Frequency stability: Better than 0.35 ppm

98-130890-D Chapter 1: General information 1-1

Output power: Refer to sections concerning Receiver / Transmitter characteristics

Supply voltage: Nominal 24V DC floating (-10 +30%)

1.2.2 Receiver characteristics

Frequency range: 150 KHz to 30 MHz

Frequency resolution: 100 Hz by keyboard entry

1-2 Chapter 1: General information 98-130890-D

Input impedance: Rx/Tx : 50 ohm