Navatech — VSAT Installation Tips & Tricks

Cable template, Direct M & C cable for PCU

This cable is for connecting the PCU direct to the antenna remote connector on the ACU. It makes it possible to upgrade a PCU without having to install the PCU in the antenna.

Tools Required

Compass / GPS / inclinometer (or app) for azimuth & elevation.
Spectrum analyzer or satellite finder with beacon lock.
Torque wrench & stainless hardware; thread locker where appropriate.
Crimp tools for connectors; heat-shrink and weatherproofing tape.
Multimeter for continuity and ground verification.
Personal protective equipment (PPE) for work at height.

Mounting & Alignment

Use a plumb mast—check in two axes. A non-plumb base introduces pointing error.
Rough-point using calculated az/el/skew; then peak on beacon with tiny movements.
Tighten in stages while peaking; re-verify after torqueing to spec.
Isolate vibration: avoid flexible handrails or thin plates; use backing plates where needed.
Set polarization/skew per network requirements; mark final positions.

RF & Cabling

Use low-loss, properly rated coax; keep runs as short as practical.
Dress cables with drip loops; avoid tight bends and pinch points.
Terminate connectors cleanly; check continuity and insulation resistance.
Ground the dish, ODU, and indoor rack to a common earth per spec.
Weatherproof all outdoor connectors (self-amalgamating + UV tape).

Cable Selection Reference

Loss values are per 30 m (100 ft).

Max Length	Cable Type	Loss per 30 m (100 ft)	Connector Type	Connector Tools
< 30 m (100 ft)	LMR 240	9.87 dB	EZ-240-NMH-D	—
< 30 m (100 ft)	RG8 / RG8/U	8.99 dB	—	—
< 50 m (160 ft)	Belden 9913	5.66 dB	—	—
< 50 m (160 ft)	LMR 400	5.13 dB	EZ-400-NMH-D	CST-400 Prep, Hex Crimp 0.429
< 60 m (200 ft)	FSJ4-50B	4.54 dB	—	—
< 60 m (200 ft)	NK-RFF 50	4.31 dB	Huber-Suhner 27322	74 Z-0-9-15
< 60 m (200 ft)	LMR 500	4.13 dB	—	—
<100 m (300 ft)	LMR 600	3.32 dB	EZ-600-NMH-D	CST-600 Prep, Hex Crimp 0.610
<100 m (300 ft)	LDF4-50A	2.77 dB	—	—
>300 ft	Fibre Optic	—	—	Recommended by SeaTel (with converters)
<200 m (600 ft)	LDF5-50A	1.58 dB	—	—
<250 m (850 ft)	LDF6-50A	1.14 dB	—	—

Values are typical; confirm exact loss at your operating frequency and connector type from vendor datasheets.

Ethernet

Ethernet UTP Cable (Unshielded) – RJ45 Male connector

The picture below shows the normal color coding for a straight through Ethernet RJ45 connection:

Crossed ETH

The picture below shows the crossed over color coding:

R11 Male connector

The RJ11 connector is used to connect to various type of voice equipment, such as the FXS ports on the Sangoma Vega 50/60 voice gateway. Only the blue/blue-white pair of the Ethernet cable is necessary in these cases, connected to the middle pair of the RJ11 connector (pin 3 and 4). Polairty is irrelevant.

LMR400

Typical use: Medium runs; see “Cable Selection Reference” above for loss guidance.
Connector: EZ-400-NMH-D
Tools: CST-400 Prep, Hex Crimp 0.429
Tips: Keep bends gentle (follow manufacturer min bend radius), avoid kinks, and dress with drip loops. Weatherproof outdoor connectors (self-amalgamating + UV tape) and label both ends.
Verification: Continuity + insulation checks; measure end-to-end loss if a meter is available.

Tools

Crimping tool
Knife
Combination plier
Side cutter
Self-amalgamating tape
UV protective electrical tape
LMR400 cable stripper

STEP 1:

First, slide the metal sleeve over the cable jacket. Straighten out the cable and cut the end squarely. Pinch the end of the cable to round the end.

STEP 2:

Use an exacto-knife and prepare the cable end to expose approx. 5mm of the center conductor. Make sure you do not cut to deep and damage the center conductor.

STEP 3:

With your hands or a plier, remove the dielectric gently by twisting carefully while pulling.

STEP 4:

Ensure the center conductor is clean of any dielectric residue and not twisted out of shape – no braid ends are to be wrapped around the center conductor. Put the connector next to the cable to measure how much (approx. 13mm) of the outer sleeve needs to be removed.

STEP 5:

With an exacto-knife, gently cut through the outer sleeve. Ensure you do not cut away any of the braid. With your hands, remove the outer sleeve gently.

STEP 6:

Slide the metal sleeve and the weather seal over the cable jacket first. All the braid must be outside of the connector body. Fold back the braid against the cable jacket - no braid ends are to be wrapped around the center conductor.

STEP 7:

If any braids are too long or sticking out, gently cut away the excess. Insert cable into connector body until dielectric is seated and ensure center conductor is inserted fully into connector center pin.

STEP 8:

Using a Crimping tool with a 0,429 inch (11mm) hex die, crimp the sleeve as close as possible to the connector body; place the connector and cable into the tool. Heat shrink the Weather Seal onto the connector body and cable jacket with a hot air gun. Alternatively, use self-amalgama-ting tape and UV protective electrical tape.

STEP 9:

Attach the connector by hand to the antenna connector. Use a 19mm wrench to tighten it securely

STEP 10:

IT IS MANDATORY to tape the connector on the antenna and ADU with self-amalgamating tape and UV protective electrical tape. First, apply self-amalgamating tape over the connection to prevent water finding its way in – take great care to get the tape properly seated around the connector and antenna base – double check that it closes the gap between connector and base 100%. Space is tight, so go slow and careful. Finish off with one layer of UV-safe electrical tape.

LMR600

Typical use: Longer runs where lower loss is required; see table above.
Connector: EZ-600-NMH-D
Tools: CST-600 Prep, Hex Crimp 0.610
Tips: Stiffer than LMR400 — pre-form gentle sweeps, support the cable to avoid weight on the connector, and keep away from sharp edges. Weatherproof thoroughly.
Verification: Continuity/insulation checks; confirm expected receive levels after install.

Tools

Crimping tool
Knife
Combination plier
Side cutter
Self-amalgamating tape
UV protective electrical tape
LMR600 cable stripper

STEP 1:

First, slide the metal sleeve over the cable jacket. Straighten out the cable and cut the end squarely. Pinch the end of the cable to round the end.

STEP 2:

Use an exacto-knife and prepare the cable end to expose approx. 5mm of the center conductor. Make sure you do not cut to deep and damage the center conductor.

STEP 3:

With your hands or a plier, remove the dielectric gently by twisting carefully while pulling.

STEP 4:

STEP 5:

With an exacto-knife, gently cut through the outer sleeve. Ensure you do not cut away any of the braid. With your hands, remove the outer sleeve gently.

STEP 6:

STEP 7:

STEP 8:

Using a Crimping tool with a 0,610 inch (16mm) hex die, crimp the sleeve as close as possible to the connector body; place the connector and cable into the tool. Ensure that the center conductor is inserted fully into connector center pin before crimping. Compress the metal sleeve by closing the tool handle completely. Heat shrink the Weather Seal onto the connector body and cable jacket with a hot air gun. Alternatively, use self-amalgamating tape and UV protective electrical tape.

STEP 9:

Attach the connector by hand to the antenna connector. Use a 19mm wrench to tighten it securely

STEP 10:

RF & RFF (Corrugated/Low-loss Coax)

Typical types: NK-RFF 50, LDF4-50A, LDF5-50A, LDF6-50A (see table for losses).
Characteristics: Rigid/corrugated construction for very low attenuation; excellent for long backbone runs.
Connectors: Use vendor-specific connectors (e.g., Huber-Suhner); follow the exact prep dimensions and torque values.
Installation notes: Maintain large bend radii, avoid repeated flexing, support the cable at regular intervals, and bond/ground per spec with proper ground kits.
Testing: DC continuity and insulation tests; sweep/return loss if equipment is available before commissioning.

Power Cable

Tools

Crimping tool for ferrules
Knife
Combination plier
Side cutter
Self-amalgamating tape
UV protective electrical tape

STEP 1:

Cut and remove 12 to 15 cm of the outer shield

STEP 2:

Remove the copper armor and plastic inner cover. Tape transition with black electrical tape.Some location want you to twist up the copper armor and connected this to GND.

STEP 3:

Remove 12 to 15 mm off the inner shield of the end. Use bootlace ferrule on the ends and remove/cut any excess wire.

Gyro Cable

Tools

Crimping tool for ferrules
Knife
Combination plier
Side cutter
Self-amalgamating tape
UV protective electrical tape

STEP 1:

Cut and remove 12 to 15 cm of the outer shield.

STEP 2:

Remove the copper armor and plastic inner cover. Tape transition with black electrical tape.

STEP 3:

Remove 12 to 15 mm off the inner shield of the end. Use bootlace ferrule on the ends and remove/cut any excess wire.

Commissioning & Testing

Verify RX level, SNR/Es/N0, and beacon stability at final torque.
Run cross-pol (if required) and record isolation values.
Check TX mute states before enabling uplink; coordinate with NOC.
Run throughput and latency tests after stabilization; log results.
Capture final photos (mount, cable routing, labels, grounding).

Gyro

Gyro Signal Verification Procedure

Tools required:

Laptop / Computer
USB to DB9 serial adapter
HyperTerminal or similar program installed
Logging cable (DB9 connector with pin 2 [RX] and pin 5 [GND] connected)

Note! Before connecting the logging cable to a GPS and GYRO source, ensure the voltage is between 1.5 to 5 VDC, as higher voltage or any AC voltage may damage your computer.

Checking Gyro

cable: You can use a normal CAT V cable and wired up to a DB9 Serial. pins on the DB9 are PIN2(RX) and Pin5(GND).

HyperTerminal (or PuTTY) connection example

Step 1: Connect the serial logging cable to the computer and start HyperTerminal (or similar software like PuTTY).

Step 2: Select the correct COM port and press Configure..

Step 3 Configure the port settings (above right graphic) and press OK. Please select baud rate according to the specification of the vessel’s GYRO.

Step 4 Connect the logging cable to verify the GYRO source signal. The reading should show an applicable heading signal.

If no info from the terminal, try to swap the cables.

Common Mistakes

Mounting on flexible or corroded structures.
Skipping waterproofing on outdoor connectors.
Ignoring skew/polarization settings.
Leaving unsecured cables that flap in wind and detune alignment.

Safety

Use fall protection, tag-out procedures, and weather windows. Keep a spotter during mast work. Treat all masts and rails as potential RF exposure zones; follow site RF safety limits and lock TX when personnel are near the antenna.

Quick Checklist

Mast plumb ✔
LoS verified ✔
Az/El/Skew set ✔
Beacon peaked & torqued ✔
Grounding & waterproofing ✔
Photos & handover docs ✔