OceanTRx7TM

Maritime Stabilized VSAT System

Technical Note

Main Harness
Document: TEC32-1664-013, Revision A
January 2013

COMMUNICATION WITHOUT BOUNDARIES

Orbit Communication Systems Ltd. P.O.B. 42504, Israel, Tel: +(972) 9 892 2777, Fax: +(972) 9 885 5944 www.orbit-cs.com
 Copyright
© 2013 Orbit Communication Systems Ltd. All rights reserved.
All product names are trademarks of Orbit Communication Systems Ltd.
Other names are the property of the respective owners.
No part of this publication may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form or
by any means, electronic or otherwise, without the prior written permission of Orbit
Communication Systems Ltd.

Disclaimer of Warranty

Orbit Communication Systems Ltd. has made every effort to ensure the accuracy and
relevancy of the material in this document. It is expected that all sections of this
document will be read thoroughly and that all information and procedures should be
fully understood.
However, Orbit Communication Systems Ltd. assumes no responsibility for any errors
that may appear in this document, and reserves the right to make changes to the
document without notice.
Orbit Communication Systems Ltd. makes no warranty of any kind in regard to this
document, including, but not limited to, the implied warranties of merchantability and
fitness for a particular purpose.
Orbit Communication Systems Ltd. disclaims any responsibility for incidental or
consequential damages in connection with the furnishing, performance or use of this
document.
Parts of this document may be based on hardware or software developed by
third-party vendors. Orbit Communication Systems Ltd. disclaims any responsibility for
the accuracy of this document with respect to such hardware and software, and
assumes no responsibility for incidental or consequential damages arising due to
discrepancies between this document and such hardware or software.

TEC32-1664-016 OceanTRx7™ Main harness Technical Note ii

Revision History and Control

Revision History

Rev # Modified by Date Comments

Rev. A Edox

TEC32-1664-016 OceanTRx7™ Main harness Technical Note iii

About this Manual
This manual is designed to guide you through the procedures required for maintaining the
MAIN HARNESS for the OceanTRx7™ Maritime Satellite Communication System.

Text Conventions

Style Indicates Example

Text Normal descriptive text Contents

Text Words or figures that appear on the System Status

screen or that should be typed
The name of a file or directory

<Text> A key to be pressed <ESC>

TEXT The name of a hardware ANTENNA

component

Text The name of a GUI element Operation Screen

 The description of a procedure  To configure…

Notations

Indicates important information that should be noted.

Indicates a potential hazard.

Indicates the safest method of installation or an operation that must be adhered

to.

TEC32-1664-016 OceanTRx7™ Main harness Technical Note iv

Effective Releases

This document is effective for Release 1 (R1) and Release 2 (R2) of the OceanTRx7™
Maritime Satellite Communication System.

For a description of the changes between R1 and R2, refer to the OceanTRx7™ Maritime
Satellite Communication System Release Notes.

TEC32-1664-016 OceanTRx7™ Main harness Technical Note v

Table of Contents
1 Introduction ....................................................................................................................... 1

1.1 Purpose...................................................................................................................... 1

1.2 Principles ................................................................................................................... 1

1.2.1 Torque Table ......................................................................................................... 1

1.3 Main Harness Description .......................................................................................... 2

1.4 Spare Kit Contents ..................................................................................................... 3

1.5 Required Tools and Parts .......................................................................................... 3

2 Preliminary Procedures ..................................................................................................... 4

3 Replacing the Main Harness ............................................................................................. 5

3.1 Removing the Main Harness ...................................................................................... 5

3.2 Installing the Main Harness ...................................................................................... 15

4 Verification test................................................................................................................ 24

TEC32-1664-016 OceanTRx7™ Main harness Technical Note vi

1 Introduction

1.1 Purpose

The purpose of this Technical Note is to provide detailed instructions on how to replace and
configure an MAIN HARNESS.

1.2 Principles

The following principles must be followed when performing the procedures in this Technical
Note.

1.2.1 Torque Table

The following table provides the torque that should be used when tightening screws of the
listed types, as relevant.

Table ‎1-1: Torque Values

Screw Type Torque

M8 25N/m

M6 10.2N/m

M5 6N/m

M4 2.5N/m

M3 1.35N/m

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 1 of 24

1.3 Main Harness Description

The MAIN HARNEES runes through the ANTENNA and distributes power, RF and command
signals to the systems components.

The Main Harness

Figure ‎1-1: Main Harness

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 2 of 24

1.4 Spare Kit Contents

The following table provides a list of the parts in the AXIS ENCODER spare kit.

Table ‎1-2: Spare Part Kit Contents

Part Name Part No. Figure

MAIN HARNESS 31-0386-9-2

Technical Note TEC32-1664-013

1.5 Required Tools and Parts

The following table provides a list of tools and customer-supplied parts that are needed to
perform the procedures in this Technical Note.

Table ‎1-3: Required Tools and Parts

Tool/Part Name Notes Figure

Phillips screwdriver

Tie cutter

Allen keys: 1.5mm

Open/ring wrench ??mm

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 3 of 24

2 Preliminary Procedures

The following preliminary procedure must be performed before replacing the MAIN
HARNESS:

1. Perform System Shut-Down of the vessel’s main power AC Voltage terminal outside the
RADOME.

2. Open the RADOME hatch.

3. Switch off the ADE POWER BOX at the ANTENNA PEDESTAL base (located inside the
RADOME).

4. Manually rotate the PEDESTAL AXES to gain convenient access to the serviced unit.

In the following procedures, be very careful when tightening and loosening the
screws with which the parts are assembled and attached to the system. Some of
these screws are delicate and can be damaged by excess force. When using an
Allen key make sure to insert the key all the way into the screw head to avoid
thread stripping.

WARNING!
The Utility Outlet is connected directly to the vessel’s AC voltage input
terminals (125 VAC / 250 VAC). Therefore, there still exists live voltage at the
Utility Outlet after disconnecting the power supply to the ADE using the Mains
Power On/Off Switch.
Only qualified and authorized personnel are allowed to carry out system
service/maintenance procedures.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 4 of 24

3 Replacing the Main Harness

3.1 Removing the Main Harness

Step 1

Move the ANTENNA DISH

so you have access to its RF
FEED.

Cut the tie wraps securing

the MAIN HARNESS to the
SERVO DRIVER.

And Unplug the MAIN

HARNESS from the SERVO
DRIVER.

Attention: Unlock plugs

before pulling them out.

Step 2

Cut tie wraps securing The

MAIN HARNESS to the back
of the ANTENNA DISH.

Note: In R1 ANTENNA type,

The GPS is located on the
back side of the ANTENNA
DISH, you will need to
release its cable as well.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 5 of 24

 Step 3

Move the ANTENNA DISH

so you have access to its
BUCK.

Cut the tie wraps securing

the BUCK’s plug and cables.

Release and uplug the MAIN

HARNESS plugs from the
BUCK.

Step 4

Manually release and

remove the RF cable from
the BUCK.

Note: For demonstration

purposes a C-BAND BUCK
was used.

Step 5

Cut the described tie wraps

securing the MAIN
HARNESS.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 6 of 24

 Step 6

Remove the two red RF

cables form the RF splitter.

Step 7

Make sure all MAIN

HARNESS tie wraps were
removed and all connectors
were unplugged at this side
of the described tube.

Step 8

While making sure no plugs

are damaged and no cables
are scratched, gently pull
out, one by one, the MAIN
HARNESS cables from the
other end of the tube.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 7 of 24

 Step 9

Unplug the MAIN HARNESS

from the ELEVATION
SERVO DRIVER.

Attention: Unlock plugs

before pulling them out.

Step 10

Cut the tie wraps securing

the ELEVATION SERVO
DRIVER cables.

Step 11

Cut the described tie wraps

securing the MAIN
HARNESS cables.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 8 of 24

 Step 12

Make sure all MAIN

HARNESS tie wraps were
removed and all connectors
were unplugged on this side
of the frame.

Step 13

While making sure no plugs

are damaged and no cables
are scratched, gently pull
out, one by one, the MAIN
HARNESS cables from the
other end of the frame (as
described).

Step 14

Use a flat screw driver and

release the described tie
wrap.

Attention: If tie wrap is not

damaged, do not cut it, just
release it so it can be
reused.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 9 of 24

 Step 15

Make sure all MAIN

HARNESS tie wraps were
removed and all connectors
were unplugged on this side
of the MAIN HARNESS.

Step 16

While making sure no plugs

are damaged and no cables
are scratched, gently pull
out, one by one, the MAIN
HARNESS cable, as
described.

Step 16

Cut the described tie wraps

in SR-RJ chamber.

Step 17

Unplug the MAIN HARNESS

plugs located in the SR-RJ
chamber.

Attention: Unlock plugs

before pulling them out.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 10 of 24

 Step 18

Release and remove the

described MAIN HARNESS
three plugs from the ACU.

Step 19

Remove the MAIN

HARNESS RF connector
from the ACU.

Step 20

Cut the described tie wraps

securing the ACU cables.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 11 of 24

 Step 21

Remove the MAIN

HARNESS two RF
connectors from the ADMX.

Step 22

Gently un rout the ADMX two

RF cables, as described.

Step 23

Cut the tie wraps securing

the ADMX red RF cables.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 12 of 24

 Step 23

Unplug the MAIN HARNESS

from the AZIMUT SERVO
DRIVER.

Attention: Unlock plug

before pulling it out.

Step 24

Cut the tie wraps securing

the AZIMUT SERVO
DRIVER cable.

Step 25

Gently un rout the AZIMUT

SERVO DRIVER cable, as
described.

Step 26

Unplug the MAIN HARNESS

from the TILT SERVO
DRIVER.

Attention: Unlock plug

before pulling it out.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 13 of 24

 Step 27

Cut the tie wraps securing

the TILT SERVO DRIVER
cables.

Step 28

Make sure all MAIN

HARNESS tie wraps were
removed and all connectors
were unplugged on this side
of the MAIN HARNESS.

Step 29

Cut the three last tie wraps

securing the MAIN
HARNESS.

Step 30

Make sure the MAIN

HARNESS is free from any tie
wrap and no plug was left
unplugged.

Remove it from the system.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 14 of 24

3.2 Installing the Main Harness

Step 1

Locate three tie warps.

Step 2

Locate the MAIN HARNESS

as illustrated

Tie the MAIN HARNESS

USING tie warp.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 15 of 24

 Step 3

Route the long side of the

MAIN HARNESS as
illustrated.

Step 4

Tie the MAIN HARNESS

USING tie warp over the
rubber sleeve and second
tie warp as illustrated.

Step 5

Route the MAIN HARNESS

as illustrated.

Step 6

Locate the MAIN HARNESS

as illustrated.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 16 of 24

 Step 7

Fold the PWR and M&C

cables.

Tie the PWR and M&C

cables and the MAIN
HARNESS to the frame as
illustrated.

Step 8

Connect the PWR and M&C

cables to the ELEVATION
SERVO DRIVER.

Step 9

Use duct tape to temporarily

secure the harness cables to
each other and protect its
plugs.

Step 10

Route the harness cables,

as illustrated.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 17 of 24

 Step 11

Tie the servo cable to the

back of the dish using tie
warps

Step 12

Connect the plugs to the

SERVO DRIVER.

Arrenge the cables and tie

them to the frame using tie
warp.

Step 13

Locate and connect the

described MAIN HARNESS
three plugs to the ACU.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 18 of 24

 Step 14

Arrenge the cables and tie

them using tie warp.

Step 15

Connect the RF cable to the

ACU.

Route the other two RF

cables as illustrated.

Step 16

Plug the MAIN HARNESS

plugs located in the SR-RJ
chamber.

Step 17

Plug the MAIN HARNESS to

the TILT SERVO DRIVER.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 19 of 24

 Step 18

Arrenge the cables and tie

them to the frame using tie
warps.

Step 19

Route the AZIMUTH SERVO

DRIVER cable as illustrated.

Step 20

Arrenge the cables and tie

them together using tie
warp.

Step 21

Plug the MAIN HARNESS to

the AZIMUTH SERVO
DRIVER.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 20 of 24

 Step 22

Route the two RF cables as

illustrated.

Step 23

Connect the RF cable to the

ADMX.

Step 24

Arrenge the cables and tie

them together to the frame
using tie warps.

Step 25

Connect the other side of

the RF cables to the RF
SPLITTER.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 21 of 24

 Step 26

Route the remain rf cable as

illustarted.

Arrenge the RF cables and

the BUC cable and tie them
together to the frame using
tie warps.

Step 27

Connect the BUC cable.

Step 27

Connect the ilustrated plug.

Step 28

Connect the ilustrated plug.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 22 of 24

 Step 29

Arrenge the cables and tie

them together to the frame
using tie warps.

Step 30

Arrenge the cables and tie

them together to the frame
using tie warps.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 23 of 24

4 Verification test

To make sure the technical process completed successfully click on Test Traj

and make sure no error messages appear in the System messages window.

TEC32-1664-016 OceanTRx7™ Main Harness Technical Note Page 24 of 24