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®
Page ii
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
Page iii
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
Page iv
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
Page v
800-10680-C, May 2007

LIST OF TABLES
Table Title Page
Table 3.1. Satellite Channel RF Antenna Cable Guide .....................................................................3-5
Page vi
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

This Page Intentionally Blank
Introduction Page 1-4
Section 1 800-10680-C, May 2007

2.0 DESCRIPTION AND OPERATION
2.1. Introduction
Handset
Cradle
Satellite
Transceiver
On-Board
RS-232
Modem
Handset
Handset Handset
Cradle
Figure 2.1. ST 3100 Satellite System Block Diagram
The AirCell®ST 3100 Satellite system provides both voice and data transfer options. The system enables
telephone communications when the aircraft is on the ground or in the air via satellite, plus the option to
have multiple handsets in the aircraft for conference-type calls.
Standard Black Handset (P/N
400-10035-00X) with Modified
Cradle (P/N 400-10038-00X)
(RJ11/RJ45 Jacks)
SatelliteTransceiver
P/N 400-10680-001 OR
P/N 400-10680-002
(non-POTS)
Standard Iridium Patch
Antenna
P/N 015-10306-001
(Top Mount Only)
Figure 2.2. ST 3100 Satellite System Standard Components
Note
Refer to AirCell®Handset Installation Guide P/N 800-10055 and AirCell®Antenna Installation Manual
P/N 800-10355 for other options and details.
Description and Operation Page 2-1
Section 2 800-10680-C, May 2007

2.2. Description and Overview
2.2.1. Handset (Standard Handset shown)
To adjust the volume on
the earpiece, press the UP
or DOWN arrows.
To receive a call, press
SND or lift the handset
and press SND.
To hang up or end a
call, press END.
The ringer volume is not
adjustable with AirCell®
corded handsets.
To place a call, enter
the phone number
and press SND.
The PWR button has no function
with a ST 3100 system
The System will come ON with the
Avionics Master. A start-up beep
will occur with a power up initiated
from the Avionics Master.
RJ-45 connector for
AirCell®Handset (RJ-
11 connector is not
used).
Secure locking for
storage.
Handset Cradle
Figure 2.3. Handset and Cradle
The handset provides voice communications and control of the AirCell®ST 3100 system. The
handset supplies and receives information to and from the Transceiver. The standard 21-inch
coil cord will extend to a little over six feet. The Handset and Cradle come in three distinctive
colors of your choice: black, beige, and gray. Mount the Handset and Cradle in any position;
however, the assembly does contain a small internal magnet, so be aware of its possible affect
on aircraft instruments and compass systems. Verify compass system deviation after the AirCell®
ST 3100 system installation is complete.
Description and Operation Page 2-2
Section 2 800-10680-C, May 2007

2.2.2. Satellite Transceiver and Mounting Tray
The AirCell®ST 3100 is
11.0” long, 3.56” wide, and 6.00”
high. The finish is textured blue
powder-coating over chemical film.
The Transceiver’s Mounting Tray
secures the unit with a flange at the
back and a locking device in the
front. Detents provide locking for
the knob, to ensure that the
Transceiver will stay in place when
it experiences vibration. A split,
rolled tube provides spring tension
to keep the knob locked in position.
An optional rail mounting kit is also
available (refer to Section 6.0 for
details).All of the electrical
connections to the Transceiver are
on the front of the box, which offers
convenient access for
maintenance. The location of the
Transceiver in the equipment rack,
may suggest the use of 90º
connectors. Access to the audio
adjustments on the top of the unit
should be a factor in the equipment
location.
Figure 2.4. ST 3100 Transceiver
System Connector Per
MS3114; Insert
Arran
g
ement 16-26P
Satellite Antenna; Type N
Female Connector
Auxiliary Connector
per M83723/73 ; Insert
Arran
g
ement 14-15S
Access Door for
Mic Bias/Audio
Level Ad
j
ust
Refer to Section 7.1., System
Specifications, for details regarding
the environmental requirements for
this unit.
Figure 2.5. ST 3100 Transceiver Mounting Tray
The Mounting Tray is alodine-processed aluminum (Chem Film per MIL-C-5541, class 3 or equivalent) to
reduce the possibility of corrosion and to provide a stable grounding path. Four (4) #6 fasteners (i.e. MS
35206-229) are used to secure the tray to the aircraft structure. Location considerations for the Mounting
Tray (P/N 800007-1) are: accessibility for maintenance; lengths of required cables; and wiring. Section
7.0, System Specifications, identifies the environmental requirements of the Transceiver. The optional
Mounting Rails (P/N 151-10689-001) are alodine-processed aluminum (Chem Film permit-C-5541, Class
3 or equivalent). Optional Rails are mounted to the Transceiver via six (6) #6 fasteners (i.e., MS51957-
27), four (4) to six (6) #8 fasteners are used to secure the Mounting Rails to the aircraft structure.
Flange and side
retention to secure
the Transceiver. Split tube offers spring
tension to the locking
device.
Detents
Description and Operation Page 2-3
Section 2 800-10680-C, May 2007

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.
Note
Component Bonding
As with any communication equipment, bonding the equipment to ground is essential for optimum
performance. Ensure that the Receiver/Transmitter Mounting Tray is bonded to the shelf, and the
shelf is bonded to airframe ground. Properly bonded, there should be 2.5 milliohms or less
between the Mounting Tray and airframe ground. Care in bonding has been shown to eliminate
erratic or poor system performance.
Note
Access Door for Audio Level, Side Tone Adjustment, and Mic Bias
Installation of multiple Handsets may require audio level adjustments for each Handset. Access
the 14 turn potentiometers by removing the small cover at the top of the unit. Use caution as the
two (2) screws are not captive and can be easily lost. The adjustments are set to mid-range at
the factory. Refer to Section 4.7.1. for Audio Level, Side Tone Adjustment, and Mic Bias
adjustment details. Refer to Section 10.0 for the Wiring Diagram for details on the separate
Handset A, B, and C audio channels, and Audio Panel interface.
2.2.3. Satellite Patch Antenna (Standard Antenna Shown)
The AirCell® Satellite Patch Antenna is P/N 015-10306-
001. This antenna is a low profile Iridium/GPS antenna
that provides continuous coverage from 1565
Megahertz (MHz) to 1626.5 MHz for excellent Iridium
applications. Mechanical configuration is a spherical-
radius molded radome that provides enhanced
protection against rain, ice, and lightening strikes.
Qualified for high-speed military aircraft as well as
general aviation applications, it has a TNC Female
connector.
Figure 2.6. Satellite Patch Antenna
Requirements of the applicable FARs may stipulate that proper Designated Engineering
Representative (DER) engineering documents (8110-3) be supplied or that the installation be
performed in accordance with an acceptable Supplemental Type Certificate (STC) for mounting
these types of antennas. These are the responsibilities of the Installer.
Note
Antenna Bonding
As with any communication equipment, bonding the Antenna to airframe is essential for optimum
performance. Ensure that the antenna is bonded to the aircraft skin. Properly bonded, there
should be 2.5 milliohms or less between the mounting screws and airframe ground. Care in
bonding has been shown to eliminate erratic or poor system performance. Iridium Antenna
bonding is essential for proper performance (as with any antenna).
Description and Operation Page 2-4
Section 2 800-10680-C, May 2007

3.0 INSTALLATION PROCEDURES
3.1. Planning
Careful planning for the install of the AirCell®ST 3100 system will ensure an efficient installation with
minimum down time for the aircraft and will ensure optimal system performance and easy maintenance
access in the future. Study the aircraft for optimal antenna location, plan equipment locations with service
in mind, and select the proper cabling before ordering. The Customer will be pleased to get the aircraft
back in service promptly as the result of your planning.
Refer to Aircraft manufacturing guidelines and/or to FAA AC 43.13-1B and -2A. FAA AC 43.13-1B
(Acceptable Methods, Techniques, and Practices) Chapter 11, and FAA AC 43.13-2A (Acceptable
Techniques, and Practices-Aircraft Alterations) Chapters 2 and 3 provide excellent guidelines to ensure a
good installation.
A field-approved FAA Form 337 that references a STC as a basis for a follow-on field approval,
references to acceptable approvable data and/or DER documentation (Form 8110-3) approving
installation data, is the usual required documentation path for the installation of this system.
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.
Note
Requirements of the applicable FARs may stipulate that proper DER engineering documents
(Form 8110-3) be supplied or that the installation be performed in accordance with an acceptable STC.
3.2. Equipment Location
If this is a new installation of an AirCell®ST 3100 system, you will need to comply with the installation
instructions of this manual, FARs, and FCC requirements by selecting RF cabling to satisfy the approved
requirements of the system. Keep the cable attenuation as low as possible in the cable run from the ST
3100 Transceiver to the Satellite Antenna, as the performance of the system will be greatly affected by
this cable attenuation.
Mount the Transceiver where rain or harsh environments will not be present. Refer to System
Specifications, Section 7.0, for further details regarding the environment requirements, as the AirCell®ST
3100 Transceiver is not weather proof. Avoid a completely “sealed” chamber, as ambient air movement
is required to cool the AirCell®ST 3100 Transceiver. When considering the use of ram-air for cooling,
ensure that rainwater will not be ingested and sprayed onto the equipment. Cooling can extend the Mean
Time Between Failure (MTBF) of electronic equipment located in a tightly packed avionics bay, so a fan
may be a worthwhile consideration.
Installation Procedures Page 3-1
Section 3 800-10680-C, May 2007

3.3. Cable Routing
Draw a cable routing diagram for the aircraft. Refer to Wiring Diagrams, Section 10.0, to determine the
required cables, then measure and record the required cable lengths on a worksheet. Consider the use
of straight or 90 degree connectors to satisfy the bend radius requirements of the coax and allow for
access to the top of the AirCell®ST 3100 Transceiver to make required audio adjustments. Allow for
adequate bend radius, service loops, and stress relief in all cable routes. Follow the cable specifications
of Tables 3.1. Clear and concise specifications when ordering parts will ensure an efficient installation.
The Vendors provide cable loss decibel (dB) and VSWR data for the aircraft records.
3.4. Antenna Selection
Refer to AirCell®Antenna Installation Manual P/N 800-10355 for options and installation details.
3.5. Handset Selection
Refer to AirCell®Handset Installation Guide P/N 800-10055 for options and installation details.
3.6. ST 3100 Transceiver Location
Typically, the AirCell®ST 3100 Transceiver would be located in the avionics equipment bay. However,
when choosing the location of the AirCell®ST 3100 Transceiver, the requirement to keep the cable loss
below 3.0 dB from the AirCell®ST 3100 Transceiver to the Satellite Antenna and loss less than 3.0 dB
from satellite antenna to Transceiver are major considerations. This requirement is to ensure the best
overall system performance. Refer to Table 3.1 to properly select the coax cables required to meet these
requirements.
Note
Some of the RG-style cables used in General Aviation applications are NOT ACCEPTABLE when
installing the AirCell®ST 3100 system.
3.7. Power, Handset, and Audio Cabling
When considering the location of the AirCell®ST 3100 Transceiver, longer Handset cabling rather than
longer antenna cable runs will enhance the performance of the system. Use shielded twisted pairs of
wire, as shown in Wiring Diagrams, Section 10.0, to reduce interference. Size the power leads to
maintain the proper supply voltage within the limits identified in System Specifications, Section 7.0, and
satisfy the requirements of FAA AC 43.13-1B. The telephone system will detect low battery voltage and
shut the system off.
3.8. Ring Detect
The Ring Detect (refer to Wiring Diagrams, Section 10.0) offers an annunciator function to be made
available in the aircraft. The operating conditions are as follows:
1) Pin G will go low (ground) when the telephone rings for an incoming call. Use this logic for a
visual annunciator or a Sonalert. Pin G will be low (ground) for one (1) second and off (open) for
three (3) seconds. This cycle will continue until the telephone is answered or the call attempt is
terminated.
2) Pin G will go low (ground) when there is an “Intercom Alert” signal received by the Transceiver.
Pin G will remain low (ground) for the duration of the intercom alert switch being energized.
Installation Procedures Page 3-2
Section 3 800-10680-C, May 2007

Note
The addition of some type of external annunciation is advisable, if only the AirCell®Cordless Handsets
are to be installed. This is due to the AirCell®Cordless Handsets having a lower ringer volume than the
corded types. The AirCell®Cordless Handset ringer can be turned down to a level that might not be
noticed in a noisy aircraft environment.
3.9. Intercom Alert
The Intercom Alert seeks a low (ground) from a momentary push button switch located near the
telephone handsets (refer to Wiring Diagrams, Section 10.0). Activation of this momentary switch will
alert the other Handset stations that intercom activity is requested. Use this logic to activate an
annunciator or Sonalert on the Ring Detect output.
3.10. Cabling
Note
Wire and Coax Installation
Installation of wire and antenna coax cables should be installed according to approved aircraft
manufacturing guidelines and/or FAA procedures documented in AC 43.13-1B. Consider cable slack,
protection from heat, and protection from chafing when installing system wiring.
Good installation practices will ensure maximum performance from the ST 3100 System. FAA AC 43.13-
2A (Acceptable Techniques, and Practices - Aircraft Alterations), Chapter 2.27, and FAA AC 43.13-1B
(Acceptable Methods, Techniques, and Practices), Chapter 11 provide excellent guidelines to ensure a
good installation. When building the system wire harness and RF cables, observe the following:
1. Plan the AirCell®cable routing so that it does not interfere with flight control cables or follow
heavy current-carrying cables, hydraulic lines, or fuel lines.
2. It is essential to use Military Specification Connectors or connectors approved for use on aircraft.
3. Refer to FAA AC 43.13-1B for the proper wire types. Wiring should conform to MIL-W-22759 or
MIL-C-27500 (AC 43.13-1B, 11, 89 or AC 43.13-1B, Tables 11-11 and 11-12) as applicable.
Installation of wire and antenna cables should be according to approved FAA procedures and
follow FAA AC 43.13-1B. Consider cable slack, protection from heat, and protection from chafing
when installing system wiring.
4. This document and attached Interface Control Drawings (ICDs) only shows a suggested circuit
breaker size, wire size & type for a typical installation:
•It is the responsibility of the Installation Agency to ensure proper wire type and size and
the use of a properly rated circuit protection device (circuit breaker). In addition, ensure
that the 28 Volts Direct Current (VDC) bus the equipment is to be connected to can
handle the additional electrical load.
•Install circuit protection (circuit breaker) of the proper amperage to handle the power
requirements and protect the wiring.
•Refer to Aircraft manufacturing guidelines and/or refer to FAA Advisory Circular 43.13-
1B, Section 11 (Aircraft Electrical Systems) for the proper wire types and circuit
protection recommendations. All wiring and coax cabling shall conform to the
flammability requirements of FAR 25.869.
•Single wire conductors shall conform to Aircraft manufacturing guidelines and/or
Fluoropolymer-Insulated Society of Automotive Engineers (SAE)-AS22759, also known
as Military (MIL)-W-22759.
•Shielded wire conductors shall conform to Aircraft manufacturing guidelines and/or
Fluoropolymer-Insulated National Electrical Manufacturers Association (NEMA) WC
27500, also known as MIL-DTL-27500.
•These wires shall be used for Power, Ground, Low Speed Signal, and Shield Drains.
Installation Procedures Page 3-3
Section 3 800-10680-C, May 2007

5. To reduce EMI / RFI to an acceptable level, all signal and power lines require shielded cables.
Ground the to/from audio line shields at the Transceiver end only, (i.e., TX and RX signals).
Refer to the wiring diagrams in Section 10.0.
6. FAA-approved antenna coaxial cables are required for this installation. Part 25 aircraft must meet
FAR 25.1359 requirements, which does not allow for the use of PVC-type insulation. Refer to
Section 3.11 for coax recommendations.
7. Provide proper grounding of the equipment by isolating chassis, power return wires, and signal
grounds.
Note
Component Bonding
As with any communication equipment, bonding the equipment to airframe ground is essential for
optimum performance and lightning protection. Ensure that the equipment mounting provisions
are bonded to the shelf, and the shelf is bonded to airframe ground. Properly bonded, there
should be 2.5 milliohms or less between the Mounting Tray and airframe ground. Care in
bonding has been shown to eliminate erratic or poor system performance.
Additional Shield Drain information
As an option, up to four (4) 22 American Wire Gauge (AWG) 7” drains may be combined on a
single grounding strap and then routed to airframe chassis. The ground strap should be as short
as possible, but may be realized with a maximum of 24” of insulated (18 AWG or larger).
8. Size power wires to handle 5.0 amps @ 28 volts dc.
The Wiring Diagrams in Section 10.0 provide manufacturing instructions for the wire harnesses. Notes on
the wiring diagrams provide essential instructions that will save you needless rework during installation.
Note
When up to three (3) Handsets are wired in, individual Handset volume control via the Transceiver access
panel is possible. Additional handsets may be wired in parallel per handset circuit, but volume loading
will occur and volume adjustment at the ST 3100 Transceiver may be required. The wiring diagram in
Section 10.0 provides wiring definitions for the Audio Panel, Handsets, and RS-232 connections. Multiple
RS-232/Modem connectors are allowed, but only one (1) data appliance can be connected at a time, to
prevent appliance malfunction. The system also provides an Audio Panel interface for direct integration
into the aircraft communications system.
Good wiring practices can be obtained from FAA AC 43.13-1B and should be followed. Here are a few
reminders. Know the harness routing and equipment location before you begin fabricating the harness.
Measure and record the harness and coax lengths required and add a few feet for good measure. It is
easy to cut to fit, but hard to stretch the wires. Identify and mark the wires in accordance with AC
43.13-1B. Refer to Section 10.0., ICD 655-10680, for mating connector layouts. AirCell®strongly
recommends that you purchase coax assemblies from PIC, ECS, or EMTEQ, so that a test record
accompanies the installation data. This practice also minimizes those hard-to-track-down cabling
problems. Refer to Table 3.1. for coax recommendations.
3.11. Satellite Antenna Installation Cable Guide
Important
Refer at AirCell® Antenna Installation Manual P/N 800-10355 for details on special Inmarsat®filtering,
Iridium to Inmarsat®, and other Antenna separation details.
When the installation requires cable lengths from the Transceiver to the Satellite Antenna greater than 60
feet,please contact AirCell®Customer Service @ 1-888-286-9876 or your preferred cable Vendor.
The RF coaxial cable performance from the Transceiver to the Satellite Antenna is critical. Keep this
cable length as short as practical to enhance the satellite telephone performance. The total RF loss
Installation Procedures Page 3-4
Section 3 800-10680-C, May 2007

should not exceed 3.0 dB @ 1600 MHz and the VSWR should be less than 1.4:1, when the cable is
terminated in a 50-ohm load. Refer to Section 10.0, ICD 655-01680 (Wiring Diagrams).
Low-loss 50-ohm cable should be used for this interface. Three (3) recommended Vendors are:
Vendors Phone
PIC 1-800-742-3191
ECS 1-800-327-9473
EMTEQ 1-888-679-6170
Refer to Table 3.1., Satellite Channel RF Antenna Cable Guide, on the following page for cable lengths,
and suggested Vendors and part numbers for connectors, cables and adapters.
Satellite Channel RF Antenna Cable
Satellite
Antenna
Transceiver Cable
Suggested Part Numbers
Cable
Length
Suggested
Vendors
50-ΩType
“N” Male
Connector
50-Ω
Double
Shielded
Coax
Cable
Straight
TNC Male
Connector
Right
Angle TNC
Male
Connector
Straight
“N” Male
Connector
“N”
Female
to TNC
Male
Adapter
0-20 feet
ECS
EMTEQ
PIC
CNS922
NMS240-1
190310
311501
PFLX240-
500
S33141
CTS922
TMS240-1
190308
CTR922
TMR240-1
190309
20-40
feet
ECS
EMTEQ
PIC
CNS122
NMS400-1
190410
311201
PFLX400-
500
S22089
CTS122
TMS400-1
190408
CTR122
TMR400-1
190409
40-60
feet
ECS
EMTEQ
PIC
CNS022
NMS500-1
190410
310801
PFLX500-
500
S22089
CTS022
TMS500-1
190408
CTR022
TMR500-1
190409
60-75
feet ECS CNS002 310701 CTS002 CTR002
75-110
feet EMTEQ NMS900-1
PFLX900-
500 NMS900-1
See
Below*
*Requires an Amphenol P/N 79825 or Maury Microwave P/N 8817B
Table 3.1. Satellite Channel RF Antenna Cable Guide
Installation Procedures Page 3-5
Section 3 800-10680-C, May 2007