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Print the checklist

Print and fill the checklist during the ORS assembly: rapidspace-HowTo.ORS.Assembly.Checklist

Flash the SSD

Using the tar file containing the slapos and re6st licenses, do the following:

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:

laptop:~# cd WORKDIR/simpleran-maintenance/oss
laptop:~/WORKDIR/simpleran-maintenance/oss# ./flash_image.py flash --tar-file ORSXXX.tar BAND

Input your gitlab username and password when asked

If you are a manufacturer of Rapid.Space

Using the tar file containing the slapos and re6st licenses that Rapid.Space prepared for you, do the following

Take an empty SSD, insert the SSD in the USB to M2 SATA adaptor and then plug the USB to the portable PC.

Run the flash_image command without band and git:

laptop:~# cd WORKDIR/simpleran-maintenance/oss
laptop:~/WORKDIR/simpleran-maintenance/oss# sudo ./flash_image.py flash --tar-file ORSXXX.tar --no-band --no-git

Note down the serial number (ORSXXX) and password at the end of the output. Note down the band when you install the SSD to the ORS

Example command:

sdr@callbox-light-001:~$ cd ~/simpleran-maintenance/oss

Change ORS800-1755709360.tar and ORS800 according to your needs:

sdr@callbox-light-001:~/simpleran-maintenance/oss$ sudo ./flash_image.py flash --tar-file ~/simpleran-maintenance/data/ORS800-1755709360.tar ORS800 --no-band --no-git
# Example output
  $> chmod 755 /tmp/tmp57surwnl
  $> /home/sdr/simpleran-maintenance/oss/../utils/detect-ssd.sh
Automatically detecting SSD...
  $> lsblk --json --bytes /dev/sda
  $> wipefs -a /dev/sda
  $> dd if=/home/sdr/simpleran-maintenance/oss/../data/ssd-ors-2025-03-17.img of=/dev/sda status=progress bs=1M
7792906752 bytes (7.8 GB, 7.3 GiB) copied, 72 s, 108 MB/s
7431+1 records in
7431+1 records out
7792906752 bytes (7.8 GB, 7.3 GiB) copied, 206.459 s, 37.7 MB/s
  $> sgdisk -s /dev/sda
The operation has completed successfully.
  $> parted /dev/sda resizepart 2 468862094.0s
Information: You may need to update /etc/fstab.

  $> sgdisk -s /dev/sda                                                 
The operation has completed successfully.
  $> e2fsck -f /dev/sda2
e2fsck 1.46.5 (30-Dec-2021)
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
/dev/sda2: 202259/409600 files (0.3% non-contiguous), 1404650/1627105 blocks
  $> resize2fs -p /dev/sda2
resize2fs 1.46.5 (30-Dec-2021)
Resizing the filesystem on /dev/sda2 to 58332305 (4k) blocks.
The filesystem on /dev/sda2 is now 58332305 (4k) blocks long.

  $> mount /dev/sda2 /tmp/tmput5ibzqv
  $> find /tmp/tmput5ibzqv/etc/opt/slapos/ssl -mindepth 1 -delete
  $> find /tmp/tmput5ibzqv/etc/re6stnet -mindepth 1 -delete
  $> chmod 755 /tmp/tmput5ibzqv
  $> sed -i s/orsXX/ors800/ /tmp/tmput5ibzqv/etc/hosts /tmp/tmput5ibzqv/etc/hostname
Successfully wrote device (serial_number: ORS800, password: xxxxxx)
  $> umount /tmp/tmput5ibzqv

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

On the left is the older enclosure model for ORS with Commell LE-37G Computer, on the right is the newer one.

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:

Install the SDR main board

Warning: The SDR Main Board is very fragile, handle it with care

For the first step, you will have to deposit the board on it's right location on the bottom enclosure, it will need to be deposited exactly in it's spot, with all screw holes aligned between the board and the enclosure. If you put the board on wrong spot and then move it, it will break components:
- First place the board right above the bottom without it touching the enclosure (you will need to angle the board to avoid the red and black wires coming out of the enclosure)
- Make sure all screw holes are aligned
- Then, lower the board carefully onto the enclosure
Install the SDR main board with 17 pieces of M2.5 screws without screwing them yet. Make sure the board doesn't slide
Start by very lightly screwing all screws, then once all screws are placed tighten them all. Screws should not be screwed too tightly

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.
For ORS with Commell LE-37G Computer only: 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.
For ORS with Commell LE-37G Computer only: Connect the PC supply cables to a PTSM connector

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

This is how to install RF coaxial cables on old 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

In this step, you will need to plug all 3 RF coax cables between the enclosure and the SDR board. The connector on the boards are fragile, please handle with caution.

Start by plugging RF2 to the enclosure connector. Check if the cable can reach the SDR board connector. Don't bend the cable too much while it is plugged to the enclosure to avoid putting pressure on the connector, if it is far off from the right shape remove it and put it back in the right shape. When plugging to the SDR board, you should make sure the connector is aligned correctly to the board connector, if it is at an angle it might break the connector
Do the same with RF1, then GPS
Fix the cable to the connectors with a wrench #8.

Install SBC and close the ORS

For LE-37G SBC: How To Assemble LE-37G SBC on ORS
For Mitac SBC: How To Assemble Mitac SBC on ORS

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. Please also put a POE Warning label as shown on the images.

Flash SIM card Open-cells

Clone the ors-util repository:

user@laptop:~# git clone https://lab.nexedi.com/nexedi/ors-utils.git user@laptop:~# cd ors-utils/write-sim-card user@laptop:~# make

If you are using OpenCell SIM Card Reader

Execute this command:

Plug the SIM Card Reader and do the folowing command:

user@laptop:~# sudo ./write-sim-card --opencell -opencell_port 0 ORSXXX

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.

If it doesn't work change the opencell_port to 1, 2, 3, 4 or 5 to get the right port

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How To Assemble An ORS