AZDEC LTD INSTALLATION GUIDE FOR WORKS ORDER No.

EXAMPLE (EXAMPLE)

Two Way Infra Red Communications System (TWIRC)

DOCUMENT No. EXAMPLE/021

asd-7841.DOC

ISSUE 1

APPROVED BY Sig:-

DATE

Page 1

AZDEC LIMITED INSTALLATION GUIDE FOR WORKS ORDER No. EXAMPLE CONTENTS

1. INTRODUCTION 2. PRE-INSTALLATION PLANNING 3. FIXED UNIT INSTALLATION 4. PORTABLE UNIT INSTALLATION 5. MOBILE UNIT INSTALLATION 6. CO-LOCATED SYSTEMS 7. INSTALLATION TOOLS 8. INSTALLATION RECORDS APPENDIX A - CALCULATIONS OF POWER SUPPLY VOLTAGE DROPS

5 10 15 29 30 31 49 50

FIGURE 1 - A TYPICAL "MAN ON THE MOVE" EQUIPMENT FIGURE 2 - ANTENNA FIGURE 3 - BASELINE BASE STATION FIGURE 4 - BATTERY CHARGER FIGURE 5 - BATTERY CHARGER MOUNTING FIGURE 6 - BATTERY CHARGER INSTALLATION FIGURE 7 - TWIRC - TYPICAL SYSTEM FIGURE 8 ANTENNA COVERAGE PLAN VIEW FIGURE 9 ANTENNA COVERAGE SIDE ELEVATION FIGURE 10 ANTENNA AREA FIGURE 11 - INTERFACE CONNECTORS FIGURE 12 BATTERY CHARGER WITH 2 BATTERY PACKS LOADED FIGURE 13 MOBILE EQUIPMENT FIGURE 14 CABLE GLAND - EMC OUTER BRAID SCREEN TERMINATED FIGURE 15 CABLE GLAND - EMC SCREEN NOT TERMINATED FIGURE 16 DATA CABLE FIGURE 17 POWER CABLE FIGURE 18 AUDIO CABLE FIGURE 19 CABLE ASSEMBLY - BASE STATION & AUXILIARY POWER SUPPLY FIGURE 20 CABLE TERMINATION - ANTENNA

6 7 8 9 11 29 32 33 34 35 36 37 38 39 41 43 44 45 46 48

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0.1 Amendment Record Issue 1 Date Comment Final Installation Guide

0.2 Future Updates None known.

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0.3 Drawings

970306/201 Noise Attenuating Headset General View 970306/202 Lightweight Headset General View 970306/203 Baseline Battery Pack General View 970306/204 Enhanced Battery Pack General View 970306/206 Baseline Base Station General View 970306/207 Enhanced Base Station General View 970306/208 Battery Charger General View 970306/209 Antenna - Long Cable General View 970306/210 Auxiliary Power Supply 970306/211 Noise Attenuating Headset - Enhanced General View

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1. Introduction
1.1 Scope This document describes the procedure for installing the TWIRC System. The document is not ship specific and therefore does not specify the quantities of each unit or the area where the installation is to be made. These will be detailed in other documents normally prepared by the Weapons Project Manager (WPM). The Ship specific documents will also provide the installer with forms in order to record the serial number, date installed and any options selected for each of the items installed. This document only describes the planning and installation of the equipment and stops short of applying power to the equipment. The procedure for Setting to Work of the equipment is described in document reference EXAMPLE/032. The Document is split into 8 sections: 1. Introduction 2. Pre-Installation Planning 3. Fixed Unit Installation 4. Portable Unit Installation 5. Mobile Unit Installation 6. Co-Located Systems 7. Installation Tools 8.Typical Installation Records It is recommended that all sections are read prior to starting the installation or installation planning process. 1.2 System Description The Two Way Infra-Red Communication System is designed to allow the user to be mobile in an area and to maintain communication with other users of the TWIRC system and users of the Ships Communication system. Each TWIRC user will have a Headset & Mobile Unit which allows them to listen to other users using their earpiece and to speak to other users using their microphone. The power for the Headset & Mobile Unit will be provided by a small belt mounted battery pack on which will be mounted the user controls e.g. the Press to Speak key. The battery pack is designed to allow the user to operate in the TWIRC area for at least 4 hours without changing the battery pack (assuming a fully charged battery). The system consists a collection of Antenna mounted above head height in the designated area. The users Headset & Mobile Unit will communicate with the Antenna using Infra-Red signals in both directions. These Antenna are wired to a fixed Base Station which in turn is wired to the Ships Communication system.

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The infra-red communication to and from the Headset & Mobile Unit on any discrete system is not to any particular Antenna, therefore the user may be mobile in the area as long as the system maintains infra-red communication with the system. For this reason the Headset & Mobile Unit is designed such that the infra-red devices are located on the top of the unit.

Figure 1 - a typical "Man on the Move" equipment The above shows a typical Man on the Move equipment which consists of two units: the Headset & Mobile Unit and the Battery Pack. The TWIRC system is a digital communication system which allow the users access to up to 2 channels (Baseline System). The system is such that all users may hear the signal on the particular channel selected. In order to speak on one of the two channels the user must press the Press To Speak (PTS) key. Normal PTS discipline is necessary to ensure all users have access to the channels in order to speak. When the system is being used to communicate with the Ships Communication

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System the TWIRC system is provided with a users sidetone signal such that the signal from the user speaking is fed back to all users earpieces together with the incoming voice signal from the Ships Communication System Two systems are available the Baseline System and the Enhanced System. The Baseline system allows the user to communicate with other users on the TWIRC system and on the Ships Internal Communication System. The Enhanced System has all the facilities of the Baseline System but has the additional feature of being able to communicate with the Ships External Communication System.

Figure 2 - Antenna
970306/209 (showing direction adjustment)

In order to achieve a rigid support the adjustable bracket should be clamped to a heavy walled, square section tube of 20 by 40mm.
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Figure 3 - Baseline Base Station

970306/206 (or 970306/207 Enhanced Base Station and 970306/210 Auxiliary Power Supply are not shown these are similar but have more or less indication lamps refer to the general views for more detail)

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Figure 4 - Battery Charger

970306/208 (including 2 Battery Packs loaded)

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2. Pre-Installation Planning The sites for the Base Station, Antenna, Auxiliary Power Supply and Battery Charger shall be identified and the routing of the cabling from the Base Station to the Antenna shall be planned. 2.1 Base Station Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

The Base Station is a wall mounted unit. It shall be located in a convenient position for connection into the Ships Communication System, the Ships 24V dc supply and for connection to the Antenna system. If the system has more than 12 Antenna then refer to section 2.8 Auxiliary Power Supply. If the Base Station is one of pair used in a co-located system then refer to section 6 for additional requirements. All entry for cables into the enclosure are via glands. In order to achieve speedy replacement of the electronic components in the case of failure, all connections to the Base Station Electronics assembly are via plugs and/or sockets (including quick release terminals. For normal operation it is not necessary to gain access to the Base Station, however for initial installation, setting to work and fault based maintenance access should be possible. The planned location shall take account of this requirement. The unit shall be mounted vertically on a flat surface ensuring the there are no obstructions to the air flow past the finned heat sink on the rear of the unit. It is recommended that a space of at least 200mm is left above and below the unit. Maintenance may require access to the unit and therefore a clearance of 300mm shall be allowed in front of the unit to allow the door to be fully opened. When the maximum number of Antennas (12 per Base Station) with the maximum cable lengths the 24V Ships supply shall be able to supply up to 12A (at the minimum 18V specified for the 24V supply) and shall be fused at 15A. On systems with shorter cable lengths and less antenna the current will be significantly less. The following table defines some of the typical conditions together with the typical currents. Number of Antenna 12 12 6 6 Maximum Cable Length 400m 150m 150m 150m Supply Voltage 18V 18V 18V 24V Typical Current 7.5A 6.0A 3.0A 2.25A

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2.2 Antenna Reference: 970306/205 Antenna General View 970306/209 Antenna - Long Cable General View

The Antenna should be located at a height above the deck of approximately 2.3m and be distributed in the area in order to give maximum coverage. Figure 8 and Figure 9 shows the typical area covered by 1 Antenna. Figure 10 shows how 4 Antenna give coverage of a complex area. Actual positions of the Antenna will need to be planned based on the size and shape of the area. Suitable fixing points will need to be identified and installed if necessary prior to the installation of the TWIRC system. The General View shows details of the fixing method. The Antenna should be located such that in the case of damage to the unit it may be removed completely and replaced with a spare Antenna. 2.3 Battery Charger Reference: 970306/208 Battery Charger General View

The Battery Charger is a portable unit which may be fixed to either a horizontal or vertical surface. The unit is used to recharge the batteries of the Battery Pack used for the Man on the Move equipment. The location chosen shall allow easy operation of the Battery Charger. The reference above shows the position of the Battery Pack, insertion and withdrawal of the Battery Packs should not be hindered by its position. The sketch below shows the typical boundaries. In addition a clearance of 25mm should be allowed for above the top surface.

Figure 5 - Battery Charger Mounting

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2.4 Internal Signal and Power Cables Reference: The Data cable is of type NSN 6145 99 439 4729. The Power Cable of type NSN-6145 99 096 2821.

The Base Station to Antenna data cable run shall be planned such that the start of the run is at the Base Station and so that each Antenna is connected to the next in a Bus Configuration as shown in Figure 11 - Interface Connectors . For systems with up to 12 Antenna then the power cable will be connected to the two interfaces on the Base Station as shown in Figure 11. For over 12 Antenna then the power will be provided by Auxiliary Power supplies as required (12 Antenna per Auxiliary Power Supply). The majority of Antenna will have four cables connected to them. Two will be Data Cables and Two will be Power Cables. The exceptions are the last Antenna on the Data Bus which will only have one Data Cable and the last Antenna on the Power Buses which will only have one power cable. Each Base Station is provided with three interfaces for connecting the Antenna, one for data and two for power. The total length of the data cable, for all of the Antenna type 970306/209, shall not exceed 1000m. Each Antenna reduces the maximum data cable length by 8m. For an installation of between 1 and 6 Antenna then only one Antenna Power Cable Bus is needed. For an installation up to 12 Antenna then the power is connected by two buses on the Base Station, with up to 6 Antenna connected to each power cable. (See Figure 11). For over 12 Antenna then the Auxiliary Power supply will be needed. The cabling between Antenna and between the Base Station and the Antenna shall not have any intermediate connections. That is each cable section shall be of one piece of cable. 2.5 External Signal and Power Cables The following cables will be needed to be connected to the Base Station via the appropriate gland, plug and socket. 2.5.1 Power Input - 24V dc Reference: The recommended cable is NSN-6145 99 096 2821 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View 970306/210 Auxiliary Power Supply General View A 24V supply of up to 12A will be necessary to power the TWIRC system, with up to 12 Antenna, via the Base Station. The supply shall be fused at 15A. For larger systems each Auxiliary Power supply will require a supply of 12A fused at 15A. The two core cable shall have an overall screen which will be terminated by the gland on the Base Station or Auxiliary Power supply. See section 2.1 for typical currents. 2.5.2 Internal Ships Communications
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Reference:

The recommended cable is NSN-6145-99-892-0076. 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

The ships internal communication system may be connected to the Base Station using the socket supplied. The cable shall be a 3 pair cable with each pair screened and an overall screen. The cable entry is via a gland, the overall screen will be terminated by the gland. 2.5.3 External Ships Communications (Enhanced System only) Reference: The recommended cable is NSN-6145-99-892-0076. 970306/207 Base Station (Enhanced) General View

The ships external communication system may be connected to the Base Station using the socket supplied. The cable shall be a 3 pair cable with each pair screened and an overall screen. The cable entry is via a gland, the overall screen will be terminated by the gland. 2.5.4 Power Input Battery Charger 115V Single Phase ac The Battery Charger is a portable unit which may be fixed to either a horizontal or vertical surface. The unit will need to be connected to the ships 115V single phase ac supply. A suitable 3 pin plug will need to be fitted to the Battery Charger cable. 2.6 Co-Located System (Master/Slave) Cable (only if co-located system selected) Reference: The Master/Slave cable is of type NSN 6145 99 439 4729.

The cable between the two co-located systems shall be kept as short as possible as specified in section 6. The cable shall be of one piece and there should be no connections to the cable other than at each end. 2.7 NEMP Bonding The fixed parts of the TWIRC system are each provided with an NEMP stud (M6) which shall be connected to the ships earth consistent with ships practice. It is therefore necessary to plan the provision of suitable connection points to the ships earth. 2.8 Auxiliary Power Supply Reference: 970306/210 Auxiliary Power Supply General View

The Auxiliary Power Supply is a wall mounted unit. It shall be located in a convenient position for connection into the Ships 24V dc supply and for connection to the
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Antenna system. If the system has more than 12 Antenna then an Auxiliary Power Supply will be required for each group of 12 Antenna. All entry for cables into the enclosure are via glands. In order to achieve speedy replacement of the electronic components in the case of failure, all connections to the Auxiliary Power Supply Electronics assembly are via plugs and/or sockets. For normal operation it is not necessary to gain access to the Auxiliary Power Supply , however for initial installation, setting to work and fault based maintenance access should be possible. The planned location shall take account of this requirement. When the maximum number of Antennas (12 per Auxiliary Power Supply) with the maximum cable lengths the 24V Ships supply shall be able to supply up to 12A (at the minimum 18V specified for the 24V supply) and shall be fused at 15A. On systems with shorter cable lengths and less antenna the current will be significantly less. The following table defines some of the typical conditions together with the typical currents. Number of Antenna 12 12 6 6 Cable Length 400m 150m 150m 150m Supply Voltage 18V 18V 18V 24V Current 7.5A 6.0A 3.0A 2.25A

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3. Fixed Unit Installation

The process detailed in this section concerns the installation of the fixed units. It does not detail the setting to work of the units or the system. The setting to work is described in EXAMPLE/032. Where a section specifies that cables shall not be connected to the electronics during the installation process it is important that this restriction is observed. Power shall NOT be applied to any part of the system during the installation process. Nor should any form of electrical insulation testing be carried out on the system as this may cause damage to the equipment. The fixed units are identified in. All units shall be visually inspect for signs of damage prior to starting the installation process. 3.1 Base Station 3.1.1 Fixing Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

The Base Station is a Wall Mounted Enclosure with 4 fixing points the size and position are identified in the references above. The unit shall be mounted vertically on a flat surface ensuring the there are no obstructions to the air flow past the finned heat sink on the rear of the unit. It is recommended that a space of at least 200mm is left above and below the unit. Maintenance may require access to the unit and therefore a clearance of 300mm shall be allowed in front of the unit to allow the door to be fully opened. 3.1.2 Glands All cables enter the Base Station enclosure via glands. The glands and cables are assembled as identified in the following sections. In order to maintain the moisture resistance of the enclosure it is essential that any hole in the enclosure not being used for a gland is fitted with an appropriate Blanking Plug. These Blanking Plugs will be supplied pre-fitted to the locations where glands are optional. Do not discard any blanking plugs that are removed, they may need to be fitted to the last Antenna on the data bus or power bus.

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3.1.2.1 Data Cable Reference: Data cable type NSN 6145 99 439 4729 Figure 15 Cable Gland - EMC Screen Not Terminated Figure 16 Data Cable Figure 19 Cable Assembly - Base Station 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View 970306/230 PG9 Gland Kit NSN 5975 99 564 2923

The Data Cable shall enter the enclosure via the gland identified in the reference above, the screens shall not be terminated on the cable gland. References above show the assembly of the gland relative to the cable including the termination of the drain wires onto the drain stud. 3.1.2.2 48V Power Cables Reference: Power cable type NSN 6145 99 096 2821 Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Figure 17 Power Cable Figure 19 Cable Assembly - Base Station 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View 970306/231 PG11 Gland Kit NSN 5975 99 000 77264

There are two access points for the Antenna 48V power cables. For a system with up to 6 Antenna then it is only necessary to use one access point. The other location should be fitted with the Blanking plug which is supplied with the Base Station. The 48V Power Cables shall enter the enclosure via the glands identified in the reference above, the screens shall be terminated on the cable gland. The references above shows the assembly of the gland relative to the cable. 3.1.2.3 Audio Cables (Ships Internal and External Communication) Reference: Audio cable type NSN-6145-99-892-0076 Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Figure 18 Audio Cable Figure 19 Cable Assembly - Base Station 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View 970306/232 PG13.5 Gland Kit NSN 5975 99 151 3187

The Audio Cables to the Ships Internal and External Communication Systems shall enter the enclosure via the glands identified in the reference above, the overall screens shall be terminated on the cable gland. The individual screens shall not be terminated on the gland, these are terminated as defined in section 3.1.3. The references above show the assembly of the gland relative to the cable.
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3.1.2.4 24V Power Cable Reference: Power cable type NSN 6145 99 096 2821 Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Figure 17 Power Cable Figure 19 Cable Assembly - Base Station 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View 970306/231 PG11 Gland Kit NSN 5975 99 000 7264

The 24V Power Cables shall enter the enclosure via the gland identified in the reference above, the screen shall be terminated on the cable gland. The references above shows the assembly of the gland relative to the cable.

3.1.2.5 Master/Slave Cable Reference: Data cable type NSN 6145 99 439 4729 Figure 15 Cable Gland - EMC Screen Not Terminated Figure 16 Data Cable Figure 19 Cable Assembly - Base Station 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View 970306/230 PG9 Gland Kit NSN 5975 99 564 2923

The Master/Slave Cable (no longer than 2m) shall enter the enclosure via the gland identified in the reference above, the screens shall not be terminated on the cable gland. The references above shows the assembly of the gland relative to the cable. In the case of a single Base Station a blanking plug shall be fitted. The Blanking Plug will be supplied with the Base Station.

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3.1.3 Electrical Interfaces Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

All connections to the Base Station Electronics Assemblies are via connectors. The connections are as follows: Port 1 2 3 4 5 6 7 PCB Connector Plug/Socket P S S P S P P Type data power 48V power 48V audio +24V input data audio, PTS Function Antenna 1-12 (or more) Antenna 1-6 Antenna 7-12 Internal Communications Input Power Master/Slave External Communications

P indicates that the connection on the Electronics Assembly is a plug (pin) and therefore the connector on the cable is a socket. Figure 19 defines the method of attaching the cable socket to the end of the cable. S indicates that the connection on the Electronics Assembly is a socket and therefore the connector on the cable is a pin crimp. Figure 19 defines the method of attaching the cable pin crimp to the end of the cable. The references above shows the location and type of each port and the appropriate gland entry point. The connection to each port are shown in the following table.

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Base Station port 1

pin 1st (co-located) 1 2 3 4 5 6 1 2 1 2 1 2 3 4 5 6 7 8 9 10 1 2 1 (4) 2 (5) 3 (6) 4 (1) 5 (2) 6 (3) 1 2 3 4 5 6 7 8 9 10

cable data pair 1 data pair 1 data pair 1 data pair 2 data pair 2 data pair 2 48V 48V 48V 48V pair 1 pair 1 pair 1 pair 2 pair 2 pair 2 pair 3 pair 3 pair 3 24V 24V M/S pair 1 M/S pair 1 M/S pair 1 M/S pair 2 M/S pair 2 M/S pair 2 pair 1 pair 1 pair 1 pair 2 pair 2 pair 2 pair 3 pair 3 pair 3 red black drain white black drain red blue red blue

wire

function 1st (co-located) RI+ RIDO+ DO-

+48V 48V return +48V 48V return Receive Receive Transmit Transmit

4 (Internal)

blue red Internal Screen blue red Internal Screen Internal Screen blue red red blue red black drain white black drain blue red Internal Screen blue red Internal Screen Internal Screen blue red

PTS Common PTS NC PTS NO +24V 0V in RI+ (DO+) RI- (DO-) DO+ (RI+) DO- (RI-)

7 (External)

Receive Receive Transmit Transmit

PTS Common PTS NC PTS NO

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3.1.4 Antenna Data Cable Termination Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

The Antenna Data connection on the Electronics Assembly is a pin header (plug) Port 1 and therefore the connector on the cable is a socket. Figure 19 defines the method of attaching the cable socket to the end of the cable. Note that the Data Cable screens are terminated on the connector and are not directly connected to the gland or the enclosure. The cable shall be fitted with the socket but shall not be connected to the Base Station plug on the electronics assembly.

3.1.5 Antenna 48V Power Cable Termination Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View Figure 17 Power Cable Figure 19 Cable Assembly - Base Station

The 48V output power connections on the Electronics Assembly is a socket Port 2 and Port 3 and therefore the connector on the cable is a pin crimp. Figure 19 defines the method of attaching the cable pin crimp to the end of the cable. 3.1.6 Ships Internal Communication Cable Termination Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View Figure 18 Audio Cable Figure 19 Cable Assembly - Base Station

The Ships Internal Communication connection on the Electronics Assembly is a pin header (plug) Port 4 and therefore the connector on the cable is a socket. Figure 19 defines the method of attaching the cable socket to the end of the cable. It should be noted that the individual screens of the cable are terminated at the Base Station and therefore should not be terminated at any other point. The cable shall be fitted with the socket but shall not be connected to the Base Station plug on the electronics assembly. Connection of the plug and socket are covered in the Setting to Work Procedure.

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3.1.7 24V Input Power Cable Termination Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View Figure 17 Power Cable Figure 19 Cable Assembly - Base Station

The 24V input power connection on the Electronics Assembly is a socket Port 5 and therefore the connector on the cable is a pin crimp. Figure 19 defines the method of attaching the cable pin crimp to the end of the cable. The 24V cable shall NOT be terminated on the socket until it is isolated from the live 24V supply. Power shall NOT be applied to the system during the installation process. 3.1.8 Co-Located System (Master/Slave) Cable Termination (only if co-located system selected) Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View Figure 16 Data Cable Figure 19 Cable Assembly - Base Station

The Co-Located System connection on the Electronics Assembly is a plug Port 6 and therefore the connector on the cable is a socket. Figure 19 defines the method of attaching the cable socket to the end of the cable. The cable shall be fitted with the socket but shall not be connected to the Base Station plug on the electronics assembly. Note: This connection is associated with the Master/Slave function. 3.1.9 Ships External Communication Cable Termination Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View Figure 18 Audio Cable Figure 19 Cable Assembly - Base Station The Ships External Communication connection on the Electronics Assembly is a plug Port 7 and therefore the connector on the cable is a socket. Figure 19 defines the method of attaching the cable socket to the end of the cable. It should be noted that the individual screens of the cable are terminated at the Base Station and therefore should not be terminated at any other point. The cable shall be fitted with the socket but shall not be connected to the Base Station plug on the electronics assembly.

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3.1.10 NEMP Bonding Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

The external M6 NEMP stud shall be connected consistent with ships practice.

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3.2 Antenna Cabling Reference: The Data cable is of type NSN 6145 99 439 4729. The Power Cable of type NSN-6145 99 096 2821.

The data cable run from the Base Station to the Antenna shall be 1 bus (see section 2.4). The power cable from a Base Station may be one or two buses depending on the number of antenna and their location relative to the Base Station. Fixing of cables shall be consistent with ships practice. The termination of cables at the Antenna requires that the cable be flexible enough to allow the direction of the Antenna to be adjusted after the cable is terminated on the Antenna. This shall be achieved by leaving a gooseneck or pigtail on the end of each cable. Each of the 4 cables shall have at least 400mm of spare cable to allow for adjustment of the Antenna and termination of the cable.

Cables Power + Data Antenna

Cables Power + Data

Cables Power + Data Antenna

Cables Power + Data

The cabling between adjacent Antenna and between the Base Station and the Antenna shall not have any intermediate connections. That is each cable section shall be of one piece of cable. 3.3 Antenna 3.3.1 Fixing Reference: 970306/209 Antenna - Long Cable General View

The Antenna is single point mounted unit which is designed at allow the direction of infra-red reception to be optimised. The reference above shows the fixing method. The location and fixing point will be identified in the ship specific instructions.

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3.3.2 Electrical Interfaces Antenna Port JP1 (input) (nearest base station) on the left when viewed from the front Pin 1 2 Drain stud 3 4 Drain stud 5 6 Cable data pair 1 data pair 1 data pair 1 data pair 2 data pair 2 data pair 2 48V in 48V in Wire black red drain black white drain blue red Function DODO+ RIRI+ 48V return +48V

JP2 (output) (furthest from base station) on the right when viewed from the front

1 2 Drain stud 3 4 Drain stud 5 6

data pair 1 data pair 1 data pair 1 data pair 2 data pair 2 data pair 2 48V out 48V out

black red drain black white drain blue red

RIRI+ DODO+ 48V return +48V

3.3.3 Data Cable Connection Reference: 970306/209 Antenna - Long Cable General View Data cable type NSN 6145 99 439 4729 970306/230 PG9 Gland Kit NSN 5975 99 564 2923 Figure 15 Cable Gland - EMC Screen Not Terminated Figure 16 Data Cable Figure 20 Cable Termination - Antenna Each Antenna will be connected to typically 4 cables, two for power and two for data. The Data cables each enter the Antenna enclosure via a gland. The references above shows the assembly of the gland relative to the cable. In the case of the last Antenna on the bus it will only have one data cable gland fitted which terminates on J1. There will be no connection to J2. In order to maintain the environmental sealing of the Antenna a blanking plug (as supplied with the Base Station see section 3.1.2) shall be fitted in place of the other cable. The references above show how the cable shall be terminated including the screen. The location of the connectors is shown in the references above. The connections schedule is shown in section 3.3.2.

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3.3.4 48V Power Cable Connection Reference: 970306/209 Antenna - Long Cable General View Power cable type NSN 6145 99 096 2821 970306/231 PG11 Gland Kit NSN 5975 000 7264 Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Figure 17 Power Cable Figure 20 Cable Termination - Antenna Each Antenna will be connected to typically 4 cables, two for power and two for data. The 48V Power cables each enter the Antenna enclosure via a gland. The references above shows the assembly of the gland relative to the cable. In the case of the last Antenna on the bus it will only have one power cable gland fitted. In order to maintain the environmental sealing of the Antenna a blanking plug (as supplied with the Base Station see section 3.1.2) shall be fitted in place of the other cable. The references above show how the cable shall be terminated. The location of the connectors in the references above. The connections schedule is shown in section 3.3.2. The maximum cable lengths for the antenna power cable is defined in Appendix A. 3.3.5 NEMP bonding Reference: 970306/209 Antenna General View

The external M6 NEMP stud shall be connected consistent with ships practice.

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3.4 Auxiliary Power Supply 3.4.1 Fixing Reference: 970306/210 Auxiliary Power Supply General View

The Auxiliary Power Supply is a Wall Mounted Enclosure with 4 fixing points identified in the reference above. The unit shall be mounted vertically on a flat surface ensuring the there are no obstructions to the air flow past the finned heat sink on the rear of the unit. It is recommended that a space of at least 200mm is left above and below the unit. Maintenance may require access to the unit and therefore a clearance of 300mm shall be allowed in front of the unit to allow the door to be fully opened. 3.4.2 Glands All cables enter the Auxiliary Power Supply enclosure via glands. The glands and cables are assembled as identified in the following sections. In order to maintain the moisture resistance of the enclosure it is essential that any hole in the enclosure not being used for a gland is fitted with an appropriate Blanking Plug. These Blanking Plugs will be supplied pre-fitted to the locations where glands are optional. Do not discard any blanking plugs that are removed, they may need to be fitted to the last Antenna on the data bus or power bus.

3.4.2.1 48V Power Cables Reference: Power cable type NSN 6145 99 096 2821 Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Figure 17 Power Cable Figure 19 Cable Assembly - Base Station 970306/210 Auxiliary Power Supply General View 970306/231 PG11 Gland Kit NSN 5975 99 000 77264

There are two access points for the Antenna 48V power cables. For a system with up to 6 Antenna connected to the Auxiliary Power Supply then it is only necessary to use one access point. The other location should be fitted with the Blanking plug which is supplied with the Auxiliary Power Supply. The 48V Power Cables shall enter the enclosure via the glands identified in the reference above, the screens shall be terminated on the cable gland. The references above shows the assembly of the gland relative to the cable.

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3.4.2.2 24V Power Cable Reference: Power cable type NSN 6145 99 096 2821 Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Figure 17 Power Cable Figure 19 Cable Assembly - Base Station 970306/210 Auxiliary Power Supply General View 970306/231 PG11 Gland Kit NSN 5975 99 000 7264

The 24V Power Cables shall enter the enclosure via the gland identified in the reference above, the screen shall be terminated on the cable gland. The references above shows the assembly of the gland relative to the cable. The maximum cable lengths for the antenna power cable is defined in Appendix A.

3.4.3 Electrical Interfaces Reference: 970306/210 Auxiliary Power Supply General View

All connections to the Auxiliary Power Supply Electronics Assemblies are via connectors. The connections are as follows: Port PCB Connector Plug/Socket S S S Type Function

2 3 5

power 48V power 48V +24V input

Antenna 1-6 Antenna 7-12 Input Power

P indicates that the connection on the Electronics Assembly is a plug (pin) and therefore the connector on the cable is a socket. Figure 19 defines the method of attaching the cable socket to the end of the cable. S indicates that the connection on the Electronics Assembly is a socket and therefore the connector on the cable is a pin crimp. Figure 19 defines the method of attaching the cable pin crimp to the end of the cable. The references above shows the location and type of each port and the appropriate gland entry point.

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The connection to each port are shown in the following table. Auxiliary Power Supply port 2 pin 1st (co-located) 1 2 1 2 1 2 48V 48V 48V 48V 24V 24V cable red blue red blue red blue wire function 1st (co-located) +48V 48V return +48V 48V return +24V 0V in

3.4.4 Antenna 48V Power Cable Termination Reference: 970306/210 Auxiliary Power Supply General View Figure 17 Power Cable Figure 19 Cable Assembly - Base Station

The 48V output power connections on the Electronics Assembly is a socket Port 2 and Port 3 and therefore the connector on the cable is a pin crimp. Figure 19 defines the method of attaching the cable pin crimp to the end of the cable. 3.4.5 24V Input Power Cable Termination Reference: 970306/210 Auxiliary Power Supply General View Figure 17 Power Cable Figure 19 Cable Assembly - Base Station

The 24V input power connection on the Electronics Assembly is a socket Port 5 and therefore the connector on the cable is a pin crimp. Figure 19 defines the method of attaching the cable pin crimp to the end of the cable. The 24V cable shall NOT be terminated on the socket until it is isolated from the live 24V supply. Power shall NOT be applied to the system during the installation process. 3.4.6 NEMP Bonding Reference: 970306/206 Base Station (Baseline) General View 970306/207 Base Station (Enhanced) General View

The external M6 NEMP stud shall be connected consistent with ships practice.
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4. Portable Unit Installation 4.1 Battery Charger Reference: 970306/208 Battery Charger General View

The Battery Charger is a portable unit that may be mounted on either a horizontal or a vertical surface. The unit should be mounted to allow easy insertion and removal of the Battery Packs. For its operation it is necessary to be able to clearly see the LED located on the surface of the Battery Charger and to be able to operate the PTS and On/Off switches on the Battery Pack.

Figure 6 - Battery Charger Installation Power to the Battery Charger is from the ships 115V single phase ac supply and a suitable source of this supply is needed close to the Charger. The input power cable shall be terminated with a plug suitable for connection to the socket of the local 115V single phase ac supply. The cable connections are identified in 4.1.1. To ensure electrical safety the Green/Yellow wire (see section 4.1.1) must be connected to the ships electrical earth. 4.1.1 Electrical Interface Input power from ships supply - cable with 3 wires. Blue Brown Green/Yellow neutral 115V ac single phase with respect to the neutral wire Earth
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5. Mobile Unit Installation 5.1 Headset & Mobile Unit The Headset & Mobile Unit does not require any special installation instructions. The Headset & Mobile Unit shall only be used together with the correct Battery Pack. Headset & Mobile Unit 970306/201 970306/202 970306/211 Battery Pack 970306/203 970306/203 970306/204

The installation process is restricted to inspecting the units for signs of damage. 5.2 Battery Pack The Battery Pack does not require any special installation instructions. The Battery Pack must only be charged using the Battery Charger type 970306/208 and the Battery Pack must only be used for powering one of the Headset & Mobile Units 970306/201, 970306/202 or 970306/211. There are no user replaceable parts inside the unit and the unit should not be opened. The installation process is restricted to inspecting the packs for signs of damage. The Battery Packs are consumable items, i.e. have a limited lifetime, and at the end of their life should be disposed of according to ships instructions. The Battery Packs contain Nickel Cadmium cells.

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6. Co-Located Systems The installation procedures identified in sections 2 to 5 are for a system based on one Base Station providing the user with one internal communication channel. The TWIRC System allows for two systems to be co-located in the same area which gives the user two internal channels. The installation procedure for the second system is identical to the procedure for the first system. If one of the Systems is an Enhanced System (reference section 2.5.3) this system must be designated the Master in the setting to work procedure. The two Base Station should be mounted close to each other to allow the connection of port 6 on each system to be connected together using a cable length of no more than 2m. The cable to be used is identified in section 2.6.

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Figure 7 - TWIRC - Typical System

TWIRC SYSTEM
SHIP INTERNAL INTERFACE AUDIO TRANSMIT AUDIO RECEIVE 24V POWER BASE STATION ANTENNA ANTENNA ANTENNA ANTENNA

FIXED EQUIPMENT

SHIP EXTERNAL INTERFACE (ENHANCED ONLY) AUDIO TRANSMIT AUDIO RECEIVE PTS

HEADSET & MOBILE UNIT

HEADSET & MOBILE UNIT

BATTERY PACK

BATTERY PACK

MAN ON THE MOVE EQUIPMENT

MAN ON THE MOVE EQUIPMENT

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1.2

NORMALISED

1.0

0.8

0.6

0.4

0.2

0 -0.6 -0.4 -0.2 0 0.2 0.4 0.6

Figure 8 Antenna Coverage Plan View

Typical coverage is where the scale value of 1 is equivalent to 10 metres.

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Figure 9 Antenna Coverage Side Elevation

Typical coverage at head height is 10 metres.

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Figure 10 Antenna Area

Note: to ensure high quality coverage of the area the individual antenna plots should overlap by 2m or more.

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Figure 11 - Interface Connectors

EXT. AUDIO SOCKET EXT. COMMS.

ANTENNA
T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA SOCKET 48V POWER

7 4

2 BASE STATION 3 5 6

INT. AUDIO SOCKET 24V POWER

INT. COMMS.

24V dc

ANTENNA
T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

48V POWER MASTER/ SLAVE SOCKET ANTENNA

T

TO CO-LOCACTED SYSTEM MASTER/ SLAVE SOCKET

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

ANTENNA
T T

48V POWER S = SOCKET P = PLUG T = TERMINALS OPTIONAL ITEMS

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2 3

AUXILIARY POWER SUPPLY

24V POWER

24V dc

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Figure 12 Battery Charger with 2 Battery Packs loaded

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Figure 13 Mobile Equipment

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Figure 14 Cable Gland - EMC Outer Braid Screen Terminated Strip the Cable as follows:
application dependant 10mm

NSN 6145 99 892 0076

internal screened wires, sleeved with 3mm sleeving

outer braid screen

cable outer sleeve

NSN 6145 99 -96 2821

insulated internal wires

The following sketch shows a cross section of Cable inserted in Cable Gland. Note that the outer braid screen must be carefully spread in order that the metal cone may be inserted as shown. Tightening (3.75Nm) the Gland Nut both seals the gland to moisture and connects the EMC screen to the Enclosure.
insulated internal wires (and internal screens) PG thread metal cone outer braid screen thread gland nut cable outer sleeve

gland metal body

FOR INFORMATION ONLY, ITEMS NOT TO THE SAME SCALE

compression material

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The following sketch shows the gland kit parts assembled on a cable.

back nut

gland Fibre or Nylon washer

FOR INFORMATION ONLY, ITEMS NOT enclosure TO THE SAME SCALE

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Figure 15 Cable Gland - EMC Screen Not Terminated Strip the Cable as follows:

application dependant

cable outer sleeve

NSN 6145 99 439 4729 internal screened wires, sleeved with 3mm sleeving

The following sketch shows a cross section of Cable inserted in Cable Gland. Tightening (3.75Nm) the Gland Nut seals the gland to moisture

metal cone thread PG thread

gland nut

cable outer sleeve

internal screened wires, sleeved with 3mm sleeving

gland metal body compression material

FOR INFORMATION ONLY, ITEMS NOT TO THE SAME SCALE

The following sketch shows the gland kit parts assembled on a cable.

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back nut

FOR INFORMATION ONLY, ITEMS NOT enclosure TO THE SAME SCALE

gland Fibre or Nylon washer

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Figure 16 Data Cable

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Figure 17 Power Cable

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Figure 18 Audio Cable

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Figure 19 Cable Assembly - Base Station & Auxiliary Power Supply

Data Cable 3 mm sleeving pair 1 B R D pair 2 B W D 6 off crimp type 08-50-0108

2 mm sleeving

as required from gland

B = black R = red W - white D = drain

Power Cable red

blue 10mm as required from gland 2 off blue pin crimp as supplied in gland kit 970306/231

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Audio Cable

3 mm sleeving pair 1 B R S pair 2 B R pair 3 S S 2 mm sleeving B R B = blue R = red S = screen

as required from gland

9 off crimp type 08-50-0108

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Figure 20 Cable Termination - Antenna

data cable signal wire

10mm

2 mm sleeving data cable drain wire

Crimp red type

power cable

10mm

Crimp blue type 2 off in each gland kit 970306/231

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7. Installation Tools
The following general purpose tools will be need for the installation of the Two Way Infra Red Communications system. Item 1 Description Crimp tool type e.g. Farnell 150-352 Crimp tool type e.g. Farnell 285-500 Screw driver Superdrive No 2. Spanner M3 nut/bolt Spanner M10 nut/bolt Spanner 10mm across flats Where Used Power Cable blue & red crimps Signal Connectors Enclosure access Drain wire stud Antenna to Universal Joint NEMP Earth Studs Antenna Base Station Auxiliary Power Supply Base Station Antenna Antenna Antenna Base Station Antenna Auxiliary Power Supply Antenna Antenna Base Station Antenna Base Station Antenna Base Station Auxiliary Power Supply Antenna Base Station Auxiliary Power Supply Base Station Base Station

2 3 4 5 6

7 8 9 10

Spanner 13mm across flats Spanner 17mm across flats Spanner 18mm across flats Spanner 20mm across flats

Universal Joint Locking Nuts PG9 Gland front nut PG9 Gland back nut PG11 Gland front nut

11

Spanner 21mm across flats

PG11 Gland back nut

12 13

Spanner 22mm across flats Spanner 23mm across flats

PG13.5 Gland front nut PG13.5 Gland back nut

Wire cutters Pliers Screwdrivers Spanners

General General General General

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8. Installation Records

Base Station

Type

Serial number

Number of Power Bus Used

Date Installed

Engineer

Auxiliary Power Supply

Type

Serial number

Number of Power Bus Used

Date Installed

Engineer

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Antenna

Base Station Location on Data Bus

Power Bus From

Serial Number

Date Installed

Engineer

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Antenna

Base Station Location on Data Bus

Power Bus From

Serial Number

Date Installed

Engineer

Battery Charger

Serial Number

Date Installed

Engineer

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Headset & Mobile Unit

Type

Serial Number

Date Installed

Engineer

Battery Pack

Type

Serial Number

Date Installed

Engineer

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Battery Pack

Type

Serial Number

Date Installed

Engineer

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