AirCell ST 3100 User manual

ST 3100
Installation Manual
Satellite Telephone System
Transceiver P/N 400-10680-001 and -002
Installation Manual P/N 800-10680
Revision C, May 2007
AirCell®LLC
1172 Century Drive, Suite 280, Building B
Louisville, CO 80027
United States of America
Distribution Statement: This publication is for the Satellite Telephone products only and is to be
used by Customers and authorized AirCell® agents only. Send requests for additional copies of
this document to Corporate Publications Coordinator or e-mail at ([email protected]).

PROPRIETARY NOTICE
This document and the information disclosed herein are proprietary data of AirCell®. Neither this
document nor the information contained herein shall be used, reproduced, or disclosed to others without
written authorization of AirCell®, except to the extent required for installation of recipient’s equipment.
Notice
Freedom of Information Act (5 USC 552) and Disclosure of
Confidential Information Generally (18 USC 1905)
AirCell®is furnishing this document in confidence. The information disclosed here falls within exemption
(b)(4) of USC 552 and the prohibitions of 18 USC 1905. For further information, please contact:
Corporate Publications Coordinator
AirCell®LLC
1172 Century Drive, Suite 280, Building B
Louisville, CO 80027
Telephone: [phone]
FAX: [phone]
Copyright 2007 AirCell®LLC
All Rights Reserved
Information in this document is subject to change without notice and does not represent a commitment on
the part of AirCell®.
Trademark Acknowledgements
Inmarsat®is a registered trademark of the International Maritime Satellite Organization (IMSO) and is
licensed by IMSO to Inmarsat Limited and Inmarsat Ventures plc. Inmarsat’s product names are either
trademarks or registered trademarks of Inmarsat.
uniHub™ is a registered trademark of On-Go, Inc.
Other product and company names mentioned in this manual may be trademarks or trade names of their
respective owners.
Page i
800-10680-C, May 2007

RECORD OF REVISIONS
REVISION DESCRIPTION
RELEASE
DATE
RELEASED
BY
A Original Document October 2002 AirCell®
B
Revised to delete Handset and Antenna specific
information from this manual in order to create
separate Handset and Antenna manuals.
June 2005 AirCell®
C
Revised for the addition of the -002 non-POTS
configuration, the functionality of revised volume
potentiometers on the -001 Transceiver, and
incorporated miscellaneous editorial comments and
revisions.
May 2007 AirCell®
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800-10680-C, May 2007

TABLE OF CONTENTS
Subject Page
PROPRIETARY NOTICE...............................................................................................................................i
RECORD OF REVISIONS ............................................................................................................................ ii
TABLE OF CONTENTS .............................................................................................................................. iii
LIST OF FIGURES ....................................................................................................................................... v
LIST OF TABLES ........................................................................................................................................ vi
1.0 INTRODUCTION.............................................................................................................................1-1
1.1 General.....................................................................................................................................1-1
1.2 Unpacking................................................................................................................................1-2
1.3 Planning...................................................................................................................................1-2
1.4 List of Abbreviations and Acronyms....................................................................................1-2
1.5 Advisories................................................................................................................................1-3
1.6 List of Related Publications...................................................................................................1-3
2.0 DESCRIPTION AND OPERATION ................................................................................................2-1
2.1. Introduction.............................................................................................................................2-1
2.2. Description and Overview......................................................................................................2-2
2.2.1. Handset (Standard Handset shown) ................................................................................2-2
2.2.2. Satellite Transceiver and Mounting Tray .........................................................................2-3
2.2.3. Satellite Patch Antenna (Standard Antenna Shown)......................................................2-4
3.0 INSTALLATION PROCEDURES ...................................................................................................3-1
3.1. Planning...................................................................................................................................3-1
3.2. Equipment Location ...............................................................................................................3-1
3.3. Cable Routing .........................................................................................................................3-2
3.4. Antenna Selection ..................................................................................................................3-2
3.5. Handset Selection...................................................................................................................3-2
3.6. ST 3100 Transceiver Location...............................................................................................3-2
3.7. Power, Handset, and Audio Cabling.....................................................................................3-2
3.8. Ring Detect..............................................................................................................................3-2
3.9. Intercom Alert .........................................................................................................................3-3
3.10. Cabling.....................................................................................................................................3-3
3.11. Satellite Antenna Installation Cable Guide ..........................................................................3-4
4.0 TESTING AND SETUP...................................................................................................................4-1
4.1. Introduction.............................................................................................................................4-1
4.2. Testing .....................................................................................................................................4-1
4.3. Test Equipment.......................................................................................................................4-1
4.4. Test Results ............................................................................................................................4-1
4.5. Maintenance and Continued Airworthiness.........................................................................4-2
4.6. Telephone Operations (Standard Handset Shown) ............................................................4-3
4.7. Post-Installation Check, Programming, and Setup.............................................................4-3
4.7.1. System Check Out..............................................................................................................4-4
4.7.1.1. Audio Level Adjustments (Revision M and earlier)................................................4-4
4.7.1.2. Audio Level Adjustments (Revision N and later) ...................................................4-6
5.0 CLEANING......................................................................................................................................5-1
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800-10680-C, May 2007

TABLE OF CONTENTS
Subject Page
5.1. Introduction.............................................................................................................................5-1
5.2. Recommended Cleaning Materials .......................................................................................5-1
5.3. Procedure ................................................................................................................................5-1
6.0 FITS AND CLEARANCES..............................................................................................................6-1
6.1. Satellite Transceiver...............................................................................................................6-1
7.0 SYSTEM SPECIFICATIONS ..........................................................................................................7-1
7.1. Purpose....................................................................................................................................7-1
7.2. Product Definition...................................................................................................................7-1
7.3. Associated Reference Documents .......................................................................................7-1
7.4. Technical Specifications........................................................................................................7-1
8.0 SPECIAL TOOLS, FIXTURES, AND EQUIPMENT .......................................................................8-1
8.1. Introduction.............................................................................................................................8-1
8.2. Test Setup and Calibration ....................................................................................................8-1
9.0 PARTS LIST ...................................................................................................................................9-1
9.1. Introduction.............................................................................................................................9-1
9.2. Parts List..................................................................................................................................9-1
9.3. Associated Equipment ...........................................................................................................9-1
10.0 WIRING DIAGRAMS..............................................................................................................10-1
10.1. Wiring Diagrams ...................................................................................................................10-1
APPENDIX A: Troubleshooting Procedures......................................................................................... A-1
APPENDIX B: Instructions for Continued Airworthiness ................................................................... B-1
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800-10680-C, May 2007

LIST OF FIGURES
Figure Title Page
Figure 2.1. ST 3100 Satellite System Block Diagram ....................................................................2-1
Figure 2.2. ST 3100 Satellite System Standard Components.......................................................2-1
Figure 2.3. Handset and Cradle .......................................................................................................2-2
Figure 2.4. ST 3100 Transceiver ......................................................................................................2-3
Figure 2.5. ST 3100 Transceiver Mounting Tray ............................................................................2-3
Figure 2.6. Satellite Patch Antenna .................................................................................................2-4
Figure 4.1. Handset Keyboard .........................................................................................................4-3
Figure 4.2. ST 3100 Transceiver (Top View) (Revision M and earlier) .........................................4-5
Figure 4.3. Conference Call Audio Level, Side Tone Adjustment, and Mic Bias........................4-5
Figure 4.4. ST 3100 Transceiver (Top View) (Revision N and later).............................................4-6
Figure 4.5. Handset Volume Audio Level, Side Tone Adjustment, and Mic Bias .......................4-7
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800-10680-C, May 2007

LIST OF TABLES
Table Title Page
Table 3.1. Satellite Channel RF Antenna Cable Guide .....................................................................3-5
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800-10680-C, May 2007

1.0 INTRODUCTION
1.1 General
This installation manual (800-10680) provides the required instructions to install the AirCell®Satellite
Transceiver (ST) 3100 system (AirCell®ST 3100). This system allows for two-way communications from
the aircraft, including voice or PC (via the Iridium on-board modem). These services are available when
the aircraft is in the air or on the ground. On the ground or in the air, the satellite communications link is
provided using the Iridium LEO (Low Earth Orbit—485 miles altitude) array of 66 satellites that enable
total earth coverage.
An Iridium-approved antenna is mounted on the top of the aircraft to provide the Radio Frequency (RF)
interface for the aircraft to satellite connection. The AirCell®ST 3100 system provides options for multiple
handsets. The AirCell®ST 3100 provides three (3) handset voice channels and a single Audio Panel
interface. Optimal handset performance is realized when handsets are wired directly to a dedicated voice
channel. When required, two handsets can be wired in parallel to a single voice channel. However,
audio quality during conferencing (intercom) between handsets deteriorates when wired in this manner. If
conferencing (intercom) is required, it is best to use a separate voice channel for each handset. The
Satellite Transceiver also has an on-board modem that accepts RS-232 serial data from a Personal
Computer, Cabin Entertainment Systems and Multi-Function Display systems.
Note
ST 3100 part number 400-01680-001 has a Plain Old Telephone System (POTS) interface and the 400-
10680-002 has no POTS interface. These transceivers are identical including revision levels; the only
exception is the -002 configuration lacks a POTS module installed on the motherboard.
The ST 3100 System was tested for Operational Shock and Crash Safety to DO-160D, Section 7,
Category B. Radiated RF Interference met the conditions of DO-160D, Section 21, Category M.
Equipment Specifications are found in Section 7.0. Install the AirCell®ST 3100 Transceiver in locations
that are free of water, spray, or other fluids, whether by direct contact or condensation. When installing
the AirCell®ST 3100 system in the aircraft, carefully follow this Installation Manual.
The AirCell®ST 3100 system meets environmental requirements identified in RTCA DO-160D, as defined
in Section 4, Category F2. Any alteration of this product voids the federal Aviation Administration (FAA)
or Federal Communications Commission (FCC) certification and the AirCell®warranty. This publication is
not to be used in lieu of a Supplementary Type Certificate (STC) or any other FAA approval. FAA form
337 approval is usually required for installation of this equipment.
Note
The material in this manual is subject to change. Before planning or performing any installation operation,
check with AirCell®www.AirCelldealers.com Dealer Info website to verify that this manual is complete and
is the latest revision. The Record of Revisions, Record of Temporary Revisions, Service Bulletin List, and
List of Effective Pages found at the front of this manual must match that issued as current by AirCell®.
www.AirCelldealers.com will have additional information that may be useful such as, Technical Bulletins
and Tech Tips and Installation and Troubleshooting Tips.
Introduction Page 1-1
Section 1 800-10680-C, May 2007

AirCell®LLC welcomes your comments, suggestions, and corrections concerning this manual. Please
include in your correspondence the publication number, equipment part number, page or figure number,
and a brief description of any problem or consideration you noted. Please send your comments to:
[email protected]
or
AirCell®LLC
Corporate Publication Coordinator
1172 Century Drive, Suite 280, Building B
Louisville, Colorado 80027
1.2 Unpacking
Unpack the equipment carefully to save the integrity of the shipping package. Inspect each component
for possible shipping damage. Report any damage to AirCell®immediately. Use original packing material
to return equipment to AirCell®.
1.3 Planning
Proper and careful planning is essential for reliable system performance and ease of maintenance. The
following are some considerations to follow when planning the installation:
ÆStudy this manual carefully to get the complete picture of the installation process.
ÆVisit www.AirCelldealers.com for additional information that may be useful, such as Technical Bulletins
and Tech Tips and Installation and Troubleshooting Tips.
ÆPlan the location of the required equipment to ensure that the cable restrictions are met.
ÆVerify that adequate airflow is provided for equipment cooling.
ÆCheck cable routing, connector access (90 degree or straight), and determine cable lengths.
ÆEnsure easy accessibility to connectors for future repairs.
ÆPlan rack or tray layout to accommodate dual (side-by-side) equipment mounting.
1.4 List of Abbreviations and Acronyms
A ampere MTBF Mean Time Between Failures
AC Advisory Circular mV millivolt
ASE Aircraft Subscriber Equipment NEMA National Electrical Manufacturers
Association
AWG American Wire Gauge PC Personal Computer
dB decibel PL Parts List
DC Direct Current P/N Part Number
FAA Federal Aviation Administration POTS Plain Old Telephone System
FCC Federal Communications Commission RF Radio Frequency
ICD Interface Control Drawing SAE Society of Automotive Engineers
LRU Line Replaceable Unit ST Satellite Transceiver
mA milliampere STC Supplemental Type Certificate
milliohm .001 of an ohm V Volts
MHz Megahertz VDC Volts Direct Current
DO-160D Environmental conditions and test procedures for airborne equipment development are
produced by RTCA. The FAA generally accepts these conditions and procedures.
RTCA Radio Technical Commission for Aeronautics: a private, not-for-profit corporation that brings
industry and government together to address the needs of the aeronautical community.
Introduction Page 1-2
Section 1 800-10680-C, May 2007

1.5 Advisories
WARNING
Statements in this Section contain critical safety information. Read these statements carefully
before installing this unit.
WARNING
Observe standard safety precautions and wear safety glasses to prevent personal injury while
installing this unit in the aircraft.
WARNING
Shut off power before connecting or disconnecting the Telephone System Components (AirCell®
ST 3100 system), as voltage transients may damage the unit or the interface wiring.
WARNING
Follow the manufacturer’s safety guidelines when using any solvents, epoxies, flammable liquids,
or any other materials during the installation processes. Some of these products are toxic to the
skin, eyes, and respiratory tract. Avoid prolonged contact and use only in well-ventilated areas.
WARNING
Components or subassemblies found in this unit may contain materials such as beryllium oxide,
acids, lithium, radioactive material, mercury, etc. that can be hazardous to your health. If the
component enclosure seal is broken, precautions must be taken against personal contact or
inhalation in accordance with Occupational Safety and Health Administration (OSHA)
requirements 29 Code of Federal Regulations (CFR) 1910.1000 or superseding documents. Any
alteration of this product voids the FAA or Federal Communications Commission (FCC)
certification and the AirCell®warranty.
CAUTION
Use Isopropyl Alcohol carefully as it may react with some plastics in the area. Isopropyl Alcohol
should be used to clean connector contacts and metal parts, if required.
1.6 List of Related Publications
The following list includes related publications for the AirCell®ST 3100 Telephone system:
Publication Publication Number
AirCell®Antenna Installation Manual AirCell®800-10355
AirCell®Handset Installation Guide AirCell®800-10055
Acceptable Methods, Techniques, and Practices - Aircraft Alterations* FAA Advisory Circular
(AC) 43.13-2A
Acceptable Methods, Techniques, and Practices - Aircraft Inspection and Repair* FAA AC 43.13-1B
Environmental Conditions and Test Procedures for Airborne Equipment DO-160D
*Installation of the AirCell®ST 3100 shall be performed in accordance with these FAA Advisory
Circulars (as applicable).
Introduction Page 1-3
Section 1 800-10680-C, May 2007