Agenda
- SSD Flash
- SDR main board installation
- PC to SDR main board connections
- ORS packaging
- Panel and ERP5 processes
This tutorial teaches how to assemble an Open Radio Station, and package it if necessary (to sell it on shop.rapid.space).
Make sure you have available licences
Check you have one "AMARI NR Small Cell" and one "AMARI 4G 5G CORE D" before assembling the ORS.
Get tokens if necessary
If you don't have enough tokens on your machine, run the ors-add-token command and copy paste the tokens you got from Rapid.Space operators.
If you need to remove a token you can do the following command: sudo gedit /opt/ors-assembly/tokens
Flash the SSD
- Take an empty SSD, insert the SSD in the USB to M2 SATA adaptor and then plug the USB to your computer.
- Run the flash_image command:
- Input your gitlab username and password when asked
Supply and Requests
Ask Rapid.Space operators to supply and request the correct services.
Take out the enclosure and waterproof RJ45 connector
Warning: Please do not plug or unplug the POE RJ45 cable from the ORS while injector is powered on.
- To unplug ORS: Unplug the electrical cord between the POE injector and the electrical outlet, then the RJ45 POE
- To plug ORS: plug RJ45 POE to the ORS, then plug POE injector to electrical outlet
Doing otherwise might break some electrical components inside the ORS. Even if the ORS has been manually powered off through SSH (for those having root access) you still need to follow this procedure to unplug it.
Prepare Waterproof Cable Mount Connector
Prepare the waterproof cable mount connector from your ORS package and a shielded Ethernet cable.
Waterproof Cable Mount Connector
Split the connector to 4 parts. Note that C is inside of B.
Cut rubber ring C
Please have C cut as shown in the picture.
Note: cutting rubber ring C is in order to pass the Ethernet cable through. Instead of doing this, you can also make your Ethernet cable so the cable itself can go through the rubber without the RJ45 connector.
Pass the cable
Pass the shielded Ethernet cable through D C B A in order.
Connect parts
Connecting each part tightly as original.
Tighten the connector
Turn tight D so that there is no gap between shielded Ethernet cable and rubber ring C.
Open the enclosure
Use a hexagonal screwdriver to remove the 8 screws from the enclosure.
Apply thermal interfaces (New enclosures)
If you have a new enclosure (Enclosure V4) compatible with the new 2 x 1W PCBs, apply thermal paste and thermal sheet this way:
Apply thermal interfaces (Old enclosures)
If you have an old enclosure (Enclosure V3) compatible with the 2 x 0.5W PCBs, apply thermal paste and thermal sheet this way:
Install the SDR main board
Warning: Make sure PCB and enclosure match, new PCB v4 will break if put inside an old enclosure !
Install the SDR main board with M2.5 screws * 17. Start by very lightly screwing all screws, then once all screws are placed tighten them all. Write down the PCB board number.
Prepare the electrical wires
Take out the LED wires and close the ORS lid while cutting excess metal wire, as small metal bits landing on PCB could break it. Cut a red and black wire of 23cm for the PC supply, and strip and tin around 4mm at each side.
Connect the wires to PTSM connectors
Connect the LED wires and the PC supply cables in a PTSM connector. The metal wires should not stick out of the PTSM, cut them if necessary. Use a SIM pin to open the PTSM connector in order to insert the cable into it as shown on the image.
Twist the power supply wires
Twist the power supply wires
Connect the LED wires and RJ45 cable
Plug the PTSM connector from the LED wires in the SDR main board. Plug an armored RJ45 cable between the ORS power input and the PCB power input. If the RJ45 cable is too long, use an insulated cord to hold it in place.
Remove the plastic films
Please remove the plastic films before you plug the coax cables.
Twist the RF coaxial cables (old enclosure)
This is how to install RF coaxial cables on old enclosures. (procedure needs to be updated for new V4 enclosures)
Twist the 3 RF coaxial cables by first twisting them in the vertical plane, then the horizontal plane. Don't use pliers or tools that could break the cables, they are fragile.
Plug the RF coax cables (old enclosure)
This is how to install RF coaxial cables on old enclosures. (procedure needs to be updated for new V4 enclosures)
Plug the 3 RF coax cables. Remove the black cable sleeve on the Radio 2 as shown on the image. First put Radio 2 cable, then Radio 1, then GPS. The connector on the boards are fragile, please be careful.
Paste SBC(PC) on the enclosure
On the other part of the enclosure, install the Single Board Computer with the M3 screws. Please remove the plastic from the bottom of SBC before you paste. Fix it with 4 screws (14cm)
Install PC
Install the DDR4 SODIMM, the MSATA SSD and the PCI Express adaptor board.
Set the jumpers on the SBC
Set the jumpers on the SBC.
Connect power cable to the SBC
Please put the enclosure with SBC and the other side on the same plane like the figure shown. Connect the power cable to the SBC.
Connect the power cable between PTSM and SDR
Warning: If the power cable is plugged in the wrong order or to the wrong port you will break the PCB !
Connect the power cable in a PTSM connector and plug this connector in the SDR main board.
Connect ribbon FFC
Connect the ribbon FFC between the PCI Express adaptor board and the SDR main board.
Connect the second RJ45 cable
Connect the second RJ45 cable between the SBC and the SDR main board.
Checklist before closing the ORS
Before closing the ORS, please be 100% sure all this is correct:
- Power cable is plugged to the "PWR_PC" port on PCB and red and black wires are in the right order as shown on photo (very important)
- Both yellow jumpers are correctly placed
- SSD was flashed correctly
- The red waterproof seal is placed correctly
Close the ORS
Before closing the ORS, you can blow some compressed air on the PCB to make sure there are no metal dust on it. Also write down the PC serial number. Close the enclosure and connect the PoE cable to start the system.
Place Labels on the ORS
Place a "ORSXX" label on the interior of the case of the PC, and on the exterior of the case as shown on the images
Power on the ORS
Power on the ORS.
Update and run playbook
root@orsXX:~# apt update
root@orsXX:~# apt upgrade
root@orsXX:~# wget https://deploy.rapid.space/ors && bash ors
root@orsXX:~# cd ors-ssd-utils
root@orsXX:~/ors-ssd-utils# git pull
Make sure there are no errors during this process
Product configuration
Follow one of these tutorials depending on your case:
Flash PCB version and serial number to PCB
Replace ORS_PRODUCT and ORS_SERIAL in the following commands:
- ORS_PRODUCT: Choose from the following:
- ORS TDDB38 3.4
- ORS TDDB39 3.4
- ORS TDDB42 3.4
- ORS TDDB43 3.4
- ORS TDDB38 4.2
- ORS TDDB39 4.2
- ORS TDDB42 4.2
- ORS TDDB43 4.2
- ORS TDDB39 4.4
- ORS FDDB28 4.4
- ORS DEVBOARD 4.4
- ORS TDDN77 4.5
- ORS TDDN79 4.5
- ORS TDDB38 4.5
- ORS_SERIAL: Serial written on the PCB, (example: "B48", "D8" etc...)
root@orsXX:~# cd ors-ssd-utils/eeprom
root@orsXX:~# apt install libftdi1-2 libconfuse2
root@orsXX:~# sed -i 's/^product=.*/product="ORS_PRODUCT"/g' config.txt
root@orsXX:~# sed -i 's/^serial=.*/serial="ORS_SERIAL"/g' config.txt
root@orsXX:~# ./eeprom -w
root@orsXX:~# ./ftdi_eeprom --build-eeprom ./config.txt
root@orsXX:~# ./ftdi_eeprom --flash-eeprom ./config.txt
# Then, in order to check the flash is OK, you can do:
root@orsXX:~# ./ftdi_eeprom --read-eeprom ./config.txt
root@orsXX:~# xxd eeprom.bin
Clone the ors-util repository:
root@orsXX:~# git clone https://lab.nexedi.com/nexedi/ors-utils.git
root@orsXX:~# cd ors-utils/uicc
root@orsXX:~# make
Execute this command:
root@orsXX:~# ./write-sim-card ORS_NUMBER
Once the first SIM card is plugged, press the Enter key
Wait until all the transfer is done, then put the next sim card, and press Enter key again. Do this for all 5 SIM cards.
Test the SIM cards and ORS
Test that each SIM card can connect to the ORS by putting it in a UE. Please also test the UE can connect to the ORS from a distance with a good enough bandwidth, to make sure the connection between SDR board and ORS box is fine.
Poweroff the ORS
Poweroff the ORS
Place warning labels on the POE connectors
Please put labels saying "Do not hot plug/unplug" on the POE connectors before packaging the ORS.
Put the ORS back in the enclosure box
Write down the enclosure serial number. Then put the ORS back in the enclosure box.
Arrange the Antennas, N to SMA adaptors, and ORS mount kit in the box as shown on the image.
Prepare the ORS package with accessories
Arrange the ORS box, RJ45 POE cable, and sim cards in the box as shown on the image.
Box dimensions: 310x220x200 mm , 3.5 kg
Checklist before closing the package
Before closing the package, please be 100% sure all this is correct:
Before filling the package with package fillers, please be 100% sure you did all this correctly:
- Test all SIM cards
- Write down all serial numbers and information related to ORS (PCB, PC, Box, MAC address, password)
- Have all screws tightly screwed on the enclosure
- Have in the package:
- the ORS Box
- the power injector
- The RJ45 POE cable with its connector
- The Antennas
- The N-to-SMA adaptors
- The SIM cards
- If the ORS is to be sent outside of Europe, print the invoices for customs and put in the package before closing it
- Print the sale packing list and include in the package
Close the package
Close the package once you have gone through the checklist
ERP5 workflow
- Create production order by cloning an existing one
- Add product line with product "Open Radio System Without License" or "Open Radio System Without License v4"
- Choose correct Transformation and Variation, then click save, then reload the page
- Go to "quantity" section, and write the quantity
- Add an item of type "ORS" with the serial number of the ORS (Ex: ORS110)
- Go to the ORS item
- Add in the item description all the serial numbers and information as such (this is an example):
Computer: T180600566
Enclosure: 93000432009080007
RAM: 8GB
SSD: 64GB
PCB: E35
MAC Address: 00:03:1D:13:0E:C8
- Add product line with product "ORS Accessories Package" and put correct quantity if you are shipping accessories
- Double check "Total quantity" for each ORS variation and accessory package
- Input the Shipping Date and Delivery Date (can be the same)
- Order, then confirm Production order (be careful, you can not modify the PO after this step)
- Wait a little while
- Open "Related Internal Packing List", and go to each generate IPL
- Replace "SSD Generic" with "ORS SSD 32GB" or "ORS SSD 64GB" or "ORS SSD 128GB"
- Replace "RAM Generic" with "ORS RAM 4GB" or "ORS RAM 8GB"
- Replace "SDR Main Board" with the correct band and version
- Click on "ORS Generic PC", add an item with the serial number of the computer (Ex: T180600566)
- Click on "ORS Enclosure ...", add an item with the serial number of the box (Ex: 93000432009080007)
- Click on "SDR Main Board ...", add an item with the serial number of the board (Ex: E35)
- Ship, Receive, then Deliver IPL
- Open "Related Manufacturing Executions", and go to each ME
- Add one day to "Shipping date" to avoid conflicts with IPL
- Replace "SSD Generic" with "ORS SSD 32GB" or "ORS SSD 64GB" or "ORS SSD 128GB"
- Replace "RAM Generic" with "ORS RAM 4GB" or "ORS RAM 8GB"
- Replace "SDR Main Board" with the correct band and version
- Click on "ORS Generic PC", add an item with the serial number of the computer (Ex: T180600566)
- Click on "ORS Enclosure ...", add an item with the serial number of the box (Ex: 93000432009080007)
- Click on "SDR Main Board ...", add an item with the serial number of the board (Ex: E35)
- Ship, Receive, then Deliver ME
- Open "Related Production Packing List", and go to each PPL
- Click on "Open Radio System Without License ...", add an item of type "ORS" with the serial number of the ORS (Ex: ORS110)
- Ship, Receive, then Deliver PPL
- Double check all IPL, ME, and PPL have been delivered