Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 07-05-2019 Page 1 of 33 Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 This document has been prepared for the exclusive use of Airobotics Ltd. (Airobotics) under the direction and authority of Airobotics and shall, at all times, remain the property of Airobotics. The holder hereof acknowledges and agrees that this document contains or may contain trade secrets, copyrighted material and commercial and proprietary information, privileged and confidential, and the holder hereof further agrees that this document may not be reproduced, distributed or copied, in whole or in part, without the express prior written consent of Airobotics. In the event this manual is sold or distributed to any other party, no warranty or guarantee, expressed or implied, is made as to the accuracy, sufficiency or suitability of the materials contained herein or of any revision, supplement or bulletin hereto, and Airobotics shall not be responsible for providing revisions for this manual to any third-party to whom this document is sold or distributed to. It is understood and agreed to by such other party that it shall release, indemnify, and hold Airobotics, its officers, employees and agents harmless against any and all claims or actions of whatever nature which may arise or claim to arise from the use hereof. Page 2 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Table of Contents 1.1 1.2 2.1 2.2 Abbreviations ............................................................................................................................................. 6 Applicable Documents ............................................................................................................................. 6 About this Document ............................................................................................................................... 7 About the FTS ............................................................................................................................................ 7 3.1 3.2 3.3 The Location .............................................................................................................................................. 8 FTS Mast Unit Parts List .......................................................................................................................... 9 Preparing the Antennas for Assembly ............................................................................................... 10 3.3.1 Preparing the Main Antenna for Assembly .................................................................................. 10 3.3.2 Preparing the Taoglass Antennas for Assembly .......................................................................... 11 Mounting the Antennas on the Mast .................................................................................................. 12 Mounting the FTS Unit Box on the Mast ............................................................................................ 13 3.4 3.5 4.1 4.2 4.3 4.4 SIM Card Installation .............................................................................................................................. 15 Battery Installation .................................................................................................................................. 18 FTS Electrical Assembly ........................................................................................................................ 21 4.3.1 Connecting the Antenna Electrical Cables .................................................................................... 21 DC Electrical Panel Modifications ........................................................................................................ 24 4.4.1 Disconnecting Wires and Cables ..................................................................................................... 25 4.4.2 Installing POE Injector ....................................................................................................................... 28 Page 3 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Table of Figures Figure 1 The FTS Mast Unit box, mounted on the upper mast ......................................................................... 8 Figure 2 FTS Main Antenna bracket mounting ................................................................................................. 10 Figure 3 Taoglass RF antennas bracket mounting ........................................................................................... 11 Figure 4 Connecting the V-bracket sub-assemblies to the mast .................................................................... 12 Figure 5 The location of the FTS Mast Unit cabinet on the mast ................................................................... 13 Figure 6 Attach the hold hanging (metal pole clamp) brackets to the mast ................................................ 14 Figure 7 Attach the plate holders to the brackets and cabinet back ............................................................. 14 Figure 8 Open the lid of the FTS mast unit box .................................................................................................. 15 Figure 9 Open the lid of the RV50 cellular modem box .................................................................................... 16 Figure 10 The SIM Card holder lid ......................................................................................................................... 16 Figure 11 The orientation of the SIM cards in the SIM Card holder ............................................................... 17 Figure 12 The battery holder and its 4 screws ................................................................................................... 18 Figure 13 The battery socket ................................................................................................................................. 19 Figure 14 The Power LEDs ..................................................................................................................................... 19 Figure 15 Antenna types ......................................................................................................................................... 21 Figure 16 Cable connections in the FTS mast unit back panel ....................................................................... 22 Figure 17 The FTS mast unit back panel ............................................................................................................. 22 Figure 18 The mast unit interfaces cover panel ................................................................................................. 23 Figure 19 The mast unit interfaces panel ............................................................................................................ 23 Figure 20 The Mast main power switch .............................................................................................................. 24 Figure 21 The LAN cable from MOXA Port 4 (POE) to the 2SP4 module ...................................................... 25 Figure 22 The wire connecting the 2J4 connector to the 2F17 fuse ............................................................. 26 Figure 23 Electrical diagram of the Mast (V1 EX) DC electrical panel ........................................................... 27 Figure 24 The location of the POE-162 Injector after installation ................................................................... 28 Figure 25 Mount the POE-162 Injector on the DIN mounting rail ................................................................... 29 Figure 26 The POE+ Injector power input wiring panel terminators .............................................................. 29 Figure 27 Connect the 48V+ wire via the 1A fuse 2F17 ................................................................................... 30 Figure 28 Connect the injector power into the POE+ unit ............................................................................... 30 Figure 29 Connect cables into the RJ45 interfaces .......................................................................................... 31 Figure 30 The P1 and POE In-Use indicator LEDs ............................................................................................. 32 Page 4 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Table of Tables Table 1 Parts list for assembling the FTS Mast Unit box on the mast ............................................................ 9 Table 1 Parts list for assembling the FTS main antenna on the bracket ..................................................... 10 Table 1 Parts list for assembling the Taoglass antennas on the bracket ..................................................... 11 Table 4 Parts list for the SIM card/s ..................................................................................................................... 16 Table 4 Parts list for the SIM card/s ..................................................................................................................... 18 Table 6 Parts list for antenna cables .................................................................................................................... 21 Table 7 Parts list for DC electrical panel modifications .................................................................................... 24 Table 8 POE+ Injector power input wiring panel terminators .......................................................................... 29 Page 5 of 33 Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 1 General Information System Subsystem Component Action/Trigger Maintenance authority minimum level Time evaluation for the entire work (in hours) Mast FTS system FTS Communications Box Emergency Landing (ELS) I Level N/A Name Date Signature Composed by Itay Levitan 30/04/2019 Edited by Etay Vider 30/04/2019 Approved by Doron Krauss 30/04/2019 1.1 Abbreviations Term ELS FTS ROC Meaning Emergency Landing Site Flight Termination System Regional Operations Center 1.2 Applicable Documents
# Document Title 1. 2. 3. Optimus-1 EX - FTS User Guide Mast Deployment Guide MA02 - Mast V2 DC Electrical Panel drawing Document No. Rev. OPT1-D-094 OPT1-M-076 OPT1-W-056 01 01 02 Date xx/05/2019 10/10/2018 13/02/2019 Page 6 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Introduction to FTS 2 2.1 About this Document This document provides instructions for assembling the FTS Mast Unit Box (and related equipment) to the Optimus-1 EX Mast. The FTS Mast Unit is the FTS system component responsible for communications link between the FTS Control Box and the UAV. 2.2 About the FTS The FTS system enables to manually terminate the UAVs flight by sending a command to Land on Spot. The FTS (Flight Termination System) is a system that consists of three main sub-systems:
ROC Control Box this control box is located inside the ROC Mast Unit Box this unit located on the Mast and communicates with the UAV. This user guide deals with the assembly of the FTS Mast Unit Box (and its related equipment). The installation of the ROC Control Box is described in a separate document (refer to the FTS ROC Installation Procedure document). IMPORTANT NOTES:
1. Two people are needed to assemble the FTS Mast Unit on the mast. 2. Only professional Airobotics personnel can assemble, install and maintain the FTS Mast Unit equipment. 3. This procedure should be performed only after the mast is standing erect in its designated place, and the first section has been raised and locked into place. Page 7 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 3 FTS Mast Unit Mechanical Assembly 3.1 The Location The FTS Mast Unit box is assembled on the upper mast, as illustrated in Figure 1. Figure 1 The FTS Mast Unit box, mounted on the upper mast Page 8 of 33 OPT1-M-104 Rev.01 3.2 FTS Mast Unit Parts List The FTS Mast Unit requires the following items for assembly on the mast (see Table 1). Optimus-1 EX - FTS Mast Assembly Procedure PLM ID MM05114 Description FTS Cellular Antennas Bracket QTY 1 Image MM05112 FTS Main ANT Bracket 100108 Laird #FG9026 1 1 100109 Extruded Aluminum Mounting Bracket 2 100112 TAOGLAS #OMB.6912.03F21 MO05199 FTS Mast unit assembly MO05346 FTS Mast Plate Holder 100107 Hold hanging with rubber DIN 912 M6x40 zinc (screw) DIN 912 M6x16 zinc (screw) DIN 125 M6 st.st (washer) DIN 985 M6 st.st (Nylock nut) 2 1 4 2 4 4 4 4 Table 1 Parts list for assembling the FTS Mast Unit box on the mast Page 9 of 33 Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 3.3 Preparing the Antennas for Assembly 3.3.1 Preparing the Main Antenna for Assembly To prepare the antennas for assembly on the mast, assemble them to the antenna bracket, as illustrated in Figure 2. Figure 2 FTS Main Antenna bracket mounting PLM ID MM05112 100108 100109 Description FTS Main ANT Bracket Laird #FG9026Omnidirectional Antenna Extruded Aluminum Mounting Bracket QTY 1 1 2 Image Table 2 Parts list for assembling the FTS main antenna on the bracket Page 10 of 33 OPT1-M-104 Rev.01 3.3.2 Preparing the Taoglass Antennas for Assembly Optimus-1 EX - FTS Mast Assembly Procedure Figure 3 Taoglass RF antennas bracket mounting PLM ID 100112 MM05114 Description TAOGLAS #OMB.6912.03F21 FTS Cellular Antennas Bracket QTY 2 1 Image Table 3 Parts list for assembling the Taoglass antennas on the bracket Page 11 of 33 Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 3.4 Mounting the Antennas on the Mast To mount the antennas on the upper mast, do the following:
1. Connect the Main antenna bracket to the V-bracket thats located below the camera/whether station V-bracket (see Figure 4). Figure 4 Connecting the V-bracket sub-assemblies to the mast NOTE:
Before proceeding to the next stage of the FTS assembly procedure, raise the second section of the mast by a height of 80 cm (just below the point where it reaches its locking position). Page 12 of 33 OPT1-M-104 Rev.01 3.5 Mounting the FTS Unit Box on the Mast Optimus-1 EX - FTS Mast Assembly Procedure Figure 5 The location of the FTS Mast Unit cabinet on the mast Page 13 of 33 OPT1-M-104 Rev.01 To mount the FTS Mast Unit Box on the mast, do the following:
1. Attach the FTS cabinet to the mast with hold hanging (metal pole clamp) brackets, using Optimus-1 EX - FTS Mast Assembly Procedure the screws that were prepared in advance (see Table 1 and Figure 6). 2. Attach the Plate Holders to the cabinet walls and to the clamps using the screws, washers and Nylock nuts that were prepared in advance (see Table 1 and Figure 7). Figure 6 Attach the hold hanging (metal pole clamp) brackets to the mast Figure 7 Attach the plate holders to the brackets and cabinet back Page 14 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 4 FTS Mast Unit Electrical Assembly 4.1 SIM Card Installation To install the SIM card into the FTS mast unit box, do the following:
1. Make sure that the FTS unit isnt connected to any power source, neither AC (via POE port) or Battery power. 2. Unscrew the 4 screws from the lid of the FTS box and open the FTS cover (see Figure 8). Figure 8 Open the lid of the FTS mast unit box Page 15 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 3. Unscrew the two screws that anchor the RV50 cellular modem (see Figure 9). Figure 9 Open the lid of the RV50 cellular modem box 4. Lift the RV50 modem, and rotate it so that the SIM card holder opening is accessible
(see Figure 10) Figure 10 The SIM Card holder lid 5. Open the 2 Philips screws of the lid for the SIM Card holder. 6. Insert either 1 or 2 SIM cards. Orientation should be as illustrated in Figure 11. PLM ID 100269 Description 4G SIM Card QTY 1 or 2 Image Table 4 Parts list for the SIM card/s Page 16 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Figure 11 The orientation of the SIM cards in the SIM Card holder 7. Close the cover of the SIM card holder and screw its screws back on. 8. Screw on the RV50 modem back into the panel of the FTS mast unit box, and then close the cover of the box, with the screws. Page 17 of 33 OPT1-M-104 Rev.01 4.2 Battery Installation To install the battery into the FTS mast unit box, do the following:
Optimus-1 EX - FTS Mast Assembly Procedure 1. Unscrew the 4 screws of the battery holder (see Figure 12). Figure 12 The battery holder and its 4 screws PLM ID E005124 Description LiFePo4 2S2P FTS battery QTY 1 Image Table 5 Parts list for the SIM card/s 2. Place the battery in its socket (see Figure 13), and in the correct orientation. 3. Close the MO05202 battery cover with the 4 screws (M4X12 DIN912). Page 18 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 2S2P LiFePo4 Battery Figure 13 The battery socket 4. Connect the battery lead connector into the FTS_V1EX_MAIN_PCB (EO05016) connector J16 (see Figure 13). Power LEDs Figure 14 The Power LEDs Page 19 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 5. If the battery was connected correctly, then all the power LEDs (except D32 "POE" LED) should be turned on (see Figure 14). 6. Close the FTS unit, make sure to have the cover 4 screw firmly tightened. Page 20 of 33 Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 4.3 FTS Electrical Assembly 4.3.1 Connecting the Antenna Electrical Cables PLM ID 100266 MM05114 Description CBL Assy N-TYPE PLUG LMR 400 6'
CBL FTS 15m POE + Cable QTY 2 1 Image Table 6 Parts list for antenna cables LoRa Antenna Cellular Antenna Figure 15 Antenna types To connect the antennas to the FTS mast unit box, do the following:
1. Connect the cellular antenna cable LMR400 (PN: 100266) from the cellular antenna
(001238) to the "CELL MAIN" N TYPE connector (see Figure 16 and Figure 17). 2. Connect the LoRa antenna cable LMR400 (PN: 100266) from the LoRa antenna (001181) into "FTS MAIN" N TYPE connector (see Figure 16 and Figure 17). 3. Add the CAT7 15m (EO05277) cable into the mast cable protection sleeve. 4. Connect the CAT7 15m (EO05277) from the mast panel connection (2J10) to the FTS box POE + connector (see Figure 16 and Figure 17). 5. Connect the FTS ground cable into the mask ground bar. Page 21 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure POE +
From DC Panel 2J10 Ground From Cellular Antenna Figure 16 Cable connections in the FTS mast unit back panel From LoRa Antenna Ground POE +
From DC Panel 2J10 From Cellular Antenna From LoRa Antenna Figure 17 The FTS mast unit back panel 6. Connect the POE+ port from the FTS unit to the DC panel external connection marked as port 2J10 using the EO05277 CAT7 15m cable (see Figure 16). 7. Open the mast output interfaces cover panel (unscrew the 5 Philips head screws). Page 22 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Figure 18 The mast unit interfaces cover panel 8. Connect the CAT7 15m cable into the FTS port 2J10 2J10 Port Figure 19 The mast unit interfaces panel 9. Close the mast output interfaces cover panel (using the 5 Philips-head screws). Page 23 of 33 OPT1-M-104 Rev.01 4.4 DC Electrical Panel Modifications Optimus-1 EX - FTS Mast Assembly Procedure IMPORTANT NOTE:
Before performing any work on the DC/AC mast electrical panels, make sure to turn OFF the Mast Units main power switch, and the internal UPS switch (inside the AC cabinet)!!!
Main Power Switch Figure 20 The Mast main power switch PLM ID 001187 000140 004150 004151 000217 Description POE+ Injector LAN CAT6 Cable 0.3m Wire, 22AWG, 300V, Red, UL Wire, 22AWG, 300V, Black, UL Insulated Ferrule QTY 1 1 1m 1m 6 Image Table 7 Parts list for DC electrical panel modifications Page 24 of 33 OPT1-M-104 Rev.01 4.4.1 Disconnecting Wires and Cables Perform the following wiring modifications to the DC electrical panel:
Optimus-1 EX - FTS Mast Assembly Procedure 1. Disconnect the LAN cable that connects Port 4 from the MOXA to the 2SP4 surge protection module (see Figure 21). Figure 21 The LAN cable from MOXA Port 4 (POE) to the 2SP4 module Page 25 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 2. Disconnect the wire that connects the 2J4 connector to the 2F17 fuse (see Figure 22). Figure 22 The wire connecting the 2J4 connector to the 2F17 fuse Page 26 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Figure 23 Electrical diagram of the Mast (V1 EX) DC electrical panel Page 27 of 33 Optimus-1 EX - FTS Mast Assembly Procedure OPT1-M-104 Rev.01 NOTE:
Figure 23 illustrates an electrical diagram of the Masts DC electrical panel, after the modifications have been completed. 4.4.2 Installing POE Injector Figure 24 The location of the POE-162 Injector after installation POE-162 Injector NOTE:
If the designated location of the POE is not clear, contact the Mechanical Engineering team. Page 28 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure To install the POE-162 Injector into the DC electrical circuits box, do the following:
1. Mount the POE on the metal DIN mounting rail (see Figure 25). Figure 25 Mount the POE-162 Injector on the DIN mounting rail 2. Connect the power input wires into the POE+ injector connector panel as shown in Figure 26 and as specified in Table 8. Figure 26 The POE+ Injector power input wiring panel terminators 3. Connect the power input wires into the POE+ connector panel as follows:
Pin Number 1 2 Description 48V+
48V-
Comments Connect via 1A fuse 2F17 (see Figure 27) GND Table 8 POE+ Injector power input wiring panel terminators Page 29 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure Figure 27 Connect the 48V+ wire via the 1A fuse 2F17 4. Connect the injector power connection into the POE+ unit (see Figure 28). Figure 28 Connect the injector power into the POE+ unit Page 30 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 5. Connect the POE+ Ethernet + DC port (POE port) into CBL-00168 cable (connected into Surge protector "2SP4") (see Figure 29). 6. Connect the POE+ Ethernet port (10/100 port) into the MOXA at port 4 with short CAT6A cable (0.5m) (see Figure 29). Connect into
"2SP4" via CBL-00168 Connect to MOXA "Port 4"
Figure 29 Connect cables into the RJ45 interfaces Page 31 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 7. Turn ON the Mast main power switch (see Figure 20). 8. Make sure that the POE injector Green LED "P1" is turned on (see Figure 30). 9. Make sure that the POE injector Orange LED "POE IN-USE" is turned on (see Figure 30). P1 POE IN-USE Figure 30 The P1 and POE In-Use indicator LEDs 10. The FTS Mast Unit has been successfully installed. Page 32 of 33 OPT1-M-104 Rev.01 Optimus-1 EX - FTS Mast Assembly Procedure 5 FCC Compliance Statement This device has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in residential installations. This equipment generates uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio and television reception. However, there is no guarantee that interference will not occur in a particular installation. If this device does cause such interference, which can be verified by turning the device off and on, the user is encouraged to eliminate the interference by one or more of the following measures:
Re-orient or re-locate the receiving antenna. Increase the distance between the device and the receiver. Connect the device to an outlet on a circuit different from the one that supplies power to the receiver. Consult the dealer or an experienced radio/TV technician. WARNING! Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the users authority to operate the equipment. WARNING! A distance of at least 20cm should be maintained between the antennas and all persons during the operation of the of this device Page 33 of 33