COBHAM HGA-7001 User manual

Form #: 875-A0064
HGA-7001
Installation Manual
Document number : 862-A0089_IM
Issue : 1.6
Date : 25 June 2015
Filename : 862-A0089_IM_ISS1.6 (HGA-7001 INSTALLATION MANUAL).DOCX

HGA-7001
Installation Manual
Document: 862-A0089_IM issue 1.6 COMPANY CONFIDENTIAL
Page 3 of 45
TABLE OF CONTENTS
P AGE
1.INTRODUCTION.......................................................................................................6
1.1G ENERAL ...................................................................................................................................6
1.2A BBREVIATIONS ..........................................................................................................................7
1.3A DVISORIES ...............................................................................................................................8
1.4F RONTISPIECE ............................................................................................................................9
2.DESCRIPTION AND OPERATION ...........................................................................10
2.1D ESCRIPTION ...........................................................................................................................10
2.2L EADING P ARTICULARS ...............................................................................................................12
2.3E QUIPMENT D ESCRIPTION ............................................................................................................14
2.3.1  Mechanical Description ....................................................................................................14 
2.3.2  Electrical Description .......................................................................................................15 
2.3.3  System Interconnection ...................................................................................................15 
2.3.4  Operation .......................................................................................................................19 
2.3.5  BIT/BITE ........................................................................................................................19 
3.STORAGE AND TRANSPORTATION ........................................................................20
3.1I NTRODUCTION .........................................................................................................................20
3.2S TORAGE ................................................................................................................................20
3.3T RANSPORTATION ......................................................................................................................20
4.UNPACKING ...........................................................................................................22
4.1I NTRODUCTION .........................................................................................................................22
4.2G ENERAL .................................................................................................................................22
4.3P ACKING L IST ...........................................................................................................................22
5.MOUNTING.............................................................................................................24
5.1I NTRODUCTION .........................................................................................................................24
5.2M OUNTING L OCATION AND G ENERAL C ONSIDERATIONS ........................................................................24
5.3S TRUCTURAL M ODIFICATIONS .......................................................................................................27
5.3.1  Structural Loads ..............................................................................................................27 
5.3.2  Mounting/Adaptor Plate ...................................................................................................28 
5.4P AINTING ................................................................................................................................28
5.5S EALING .................................................................................................................................28
5.6G ROUNDING .............................................................................................................................28
5.7P ASSIVE I NTERMODULATION (PIM) ................................................................................................29
5.8M OUNTING AND R EMOVAL P ROCEDURES ..........................................................................................30
5.8.1  Limitations and Alignment ................................................................................................30 
5.8.2  Mounting Procedure ........................................................................................................30 
5.8.3  Removal Procedure .........................................................................................................35 
6.MAINTENANCE.......................................................................................................36
6.1G ENERAL .................................................................................................................................36
6.2F AULTY U NITS ..........................................................................................................................36
7.SPECIAL TOOLS, FIXTURES AND EQUIPMENT ......................................................38
7.1I NTRODUCTION .........................................................................................................................38
7.2T OOLS , FIXTURES AND EQUIPMENT .................................................................................................38
8.ILLUSTRATED PARTS LIST.....................................................................................40
8.1I NTRODUCTION .........................................................................................................................40
8.1.1  General ..........................................................................................................................40 
8.1.2  Explanation and usage.....................................................................................................40 
8.2N UMERICAL I NDEX .....................................................................................................................42

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LIST OF FIGURES
P AGE
Figure 1: ARINC 781 SATCOM System Block Diagram............................................................................10
Figure 2: Top Side of Antenna.............................................................................................................15
Figure 3: Multi-pin Connector Pin Numbers...........................................................................................15
Figure 4: HGA-7001 High Gain Antenna Connector Locations (positions relative to the hole in fuselage and
the hole size are typical) ...............................................................................................................18
Figure 5: HGA Interfaces ....................................................................................................................19
Figure 6: HGA-7001 High Gain Antenna [IPL 18-1]................................................................................22
Figure 7: HGA-7001 Tail Cap [IPL 18-5] ................................................................................................23
Figure 8: HGA-7001 Tail Cap Screws [IPL 18-30] ..................................................................................23
Figure 9: Mounting Hole Sealing Kit [IPL 18-15] ...................................................................................23
Figure 10: RF Blockage Caused By Aircraft Wing...................................................................................26
Figure 11: Grounding Screw Holes, Ground Stud and Bonding Points......................................................29
Figure 12: Cables Connected...............................................................................................................31
Figure 13: Fitting the Lanyard .............................................................................................................32
Figure 14: Tail Cap Installation............................................................................................................32
Figure 15: Fitting of Tail Cap Screws....................................................................................................33
Figure 16: Sealant Application to Sealing Cap .......................................................................................34
Figure 17: Removing the Tail Cap........................................................................................................35
Figure 18: IPL – HGA-7001 Antenna ....................................................................................................43
Figure 19: IPL – Lanyard Assembly......................................................................................................44
Figure 20: IPL – Mounting Hole Sealing Kit...........................................................................................45
LIST OF TABLES
P AGE
Table 1: HGA-7001 Equivalent Part Numbers..........................................................................................6
Table 2: Equipment Covered...............................................................................................................11
Table 3: Associated Equipment ...........................................................................................................11
Table 4: Related Publications ..............................................................................................................11
Table 5: Equipment Specifications (Sheet 1 of 3) ..................................................................................12
Table 6: Equipment Specifications (Sheet 2 of 3) ..................................................................................13
Table 7: Equipment Specifications (Sheet 3 of 3) ..................................................................................14
Table 8: Connector Pin Assignments ....................................................................................................16
Table 9: Packing List ..........................................................................................................................22
Table 10: Installation Tools, Fixtures and Equipment.............................................................................38

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1. INTRODUCTION
1.1 General
This manual provides instructions for the installation of the HGA-7001 High Gain Antenna (see part numbers
in Table 1). The HGA-7001 is an ARINC 781 compliant antenna which conforms to the Inmarsat SDM for an
Aero-H antenna, and is approved for use with Aero-H/H+, SwiftBroadband (SBB) and Swift64 SATCOM
Systems.
Table 1: HGA-7001 Part Numbers
Description Manufacturer/Supplier Part Number TSO
HGA-7001
Omnipless Manufacturing (Pty) Ltd
(Cobham SATCOM, South Africa)
677-A0173,
677-A0173-XXX -
Chelton Inc.
(Cobham Antenna Systems, Lewisville) 804-10-0015 FAA-TSO-C132
CAUTION: THE MATERIAL IN THIS MANUAL IS SUBJECT TO CHANGE. BEFORE COMMENCING WITH
INSTALLATION VERIFY THAT COMPLETE AND UP-TO-DATE PUBLICATIONS ARE BEING
USED. PLEASE REFER TO THE APPLICABLE PUBLICATION AND SERVICE BULLETIN
INDEXES.

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1.2 Abbreviations
ADI Attitude Direction Indicator
ARINC Aeronautical Radio Inc.
BSU Beam Steering Unit
dB Decibel
DLNA Diplexer/Low Noise Amplifier
ESD Electrostatic Discharge
ESDS Electrostatic Discharge Sensitive
FAA Federal Aviation Administration
HGA High Gain Antenna
HPA High Power Amplifier
IPL Illustrated Parts List
KEAS Knots Equivalent Air Speed
LNA Low Noise Amplifier
MHz Megahertz
PIM Passive Intermodulation
RF Radio Frequency
Rx Received signal
SBB SwiftBroadband
SDM System Definition Manual
SDU Satellite Data Unit
TNC Threaded Neil Concelman (connector)
Tx Transmitted signal

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1.3 Advisories
WARNING: DURING TRANSMISSION, THIS ANTENNA CAN RADIATE MICROWAVE POWER IN ANY
DIRECTION NOT SCREENED BY THE AIRCRAFT FUSELAGE. HIGH LEVELS OF RADIO
FREQUENCY RADIATION ARE CONSIDERED HARMFUL TO HEALTH. ALTHOUGH ALL
COUNTRIES HAVE NOT AGREED UPON A SINGLE VALUE, THE AMERICAN NATIONAL
STANDARDS INSTITUTE (ANSI/IEEE C95.-1999) RECOMMENDS THAT ANY PERSON IN A
CONTROLLED ENVIRONMENT SHOULD NOT BE EXPOSED TO RADIATION STRONGER
THAN 5 MW/CM2AT THE FREQUENCIES USED IN THIS SYSTEM. ACCORDINGLY, THE
OPERATOR OF THE SYSTEM SHOULD ENSURE THAT NO PERSON SHOULD APPROACH
WITHIN 2 M (6.6 FT) OF THE ANTENNA WHEN THE SYSTEM IS TRANSMITTING,
UNLESS ADEQUATE SCREENING IS PROVIDED.
WARNING: CARE SHOULD BE TAKEN WHEN MODIFYING THE AIRCRAFT’S POWER SUPPLY SYSTEM
TO SUPPORT THE INSTALLATION. ALL POWER CABLES SHOULD BE CORRECTLY
INSULATED AND INSTALLED IN ACCORDANCE WITH NORMAL AIRCRAFT
INSTALLATION PRACTICES. FAILURE TO CORRECTLY INSTALL POWER CABLES COULD
LEAD TO INJURY OR DEATH.
CAUTION: TURN OFF POWER BEFORE DISCONNECTING ANY UNIT FROM WIRING.
DISCONNECTING THE UNIT WITHOUT TURNING POWER OFF MAY CAUSE VOLTAGE
TRANSIENTS THAT CAN DAMAGE THE UNIT.
CAUTION: THE INSTALLATION OF THE SYSTEM HARDWARE MUST NOT COMPROMISE THE
SAFETY OR INTEGRITY OF THE AIRCRAFT STRUCTURE. CARE MUST BE TAKEN TO
PREVENT ANY CHANGES TO VITAL AIRCRAFT COMPONENTS OR STRUCTURES WHEN
INSTALLING THIS SYSTEM.
NOTE: CARE SHOULD BE TAKEN WHEN PLANNING THE ROUTING OF CABLES TO AND FROM
THE SYSTEM. THE INSTALLATION OF THESE CABLES MUST NOT INTERFERE WITH
EXISTING AIRCRAFT SYSTEMS OR MAKE FUTURE INTERFERENCE POSSIBLE. ALL
CABLES MUST BE CORRECTLY SECURED AND INSULATED.

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1.4 Frontispiece
Top View
Bottom View

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2. DESCRIPTION AND OPERATION
2.1 Description
The HGA-7001 High Gain Antenna is an ARINC 781 compliant low-profile, electronically-steered,
phased array SATCOM antenna. The antenna complies with the Inmarsat Aeronautical SDM
requirements for high gain service. The antenna contains an integrated beam steering unit (BSU) and
receives command information directly from the SDU. Refer to Figure 1 for a block diagram of the
SATCOM system.
Electrical interface to the antenna is made through a TNC connector for RF interface and a multi pin
connector for power and data. The connectors are accessible through a compartment under the
antenna Tail Cap [IPL 18-5].
Refer to the frontispiece for an overall view of the equipment. Table 2 lists the equipment covered by
this manual.
Table 3 is a list of associated equipment. Table 4 lists related publications.
Aircraft'sInertial
ReferenceSystem
DLNA
HPA‐ HighPowerAmplifier
HGA‐7001HighGainAntenna
IntegratedBSU
PhasedArrayAntenna
RF
Userandsysteminterfaces
Userandsysteminterfaces
SatelliteDataUnit
Control/BITE
Data
Rx Tx
Figure 1: ARINC 781 SATCOM System Block Diagram

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Table 2: Equipment Covered
Table 3: Associated Equipment
Equipment Description Part Number
DAU-7060
OR
DAU-7070
OR
ANY APPROVED DLNA
“Modified Type A” Diplexer / Low Noise Amplifier
“Type F” Diplexer / Low Noise Amplifier
677-A0179
677-A0193
DLNA ANT to RF OUT
CABLE
RF cable assembly for interconnecting the HGA-
7001 and the DLNA
660-A0605-XXX or other
approved cable
(XXX denotes the cable
length in centimetres.
Please contact the
Supplier in this regard.)
Table 4: Related Publications
Equipment Description Part Number
HGA-7001 High Gain Antenna which is ARINC 781 compliant
and conforms to the Inmarsat SDM for an Aero H
Antenna. This antenna is approved for use with
Aero-H/H+, SBB and Swift64 SATCOM systems.
677-A0173
Publication Part Number
ARINC 429 Mark 33 Digital Information Transfer System Parts 1, 2, 3
ARINC Characteristics 741 P1-9 Aviation Satellite Communications System.
ARINC Characteristics 781 Mark 3 Aviation Satellite Communications Systems,
published: November 22, 2006
Repainting HGA-7001 Antenna Application Note OP 121
RTCA DO-160E: Environmental Conditions and Test Procedures for Airborne
Equipment
HGA-7001 Wiring Diagram
HGA-7001 Outline Drawing
DAU-7060 Outline Drawing
DAU-7070 Outline Drawing
677-A0173_WD
677-A0173-00x_ODx
677-A0179_OD
677-A0193_OD

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2.2 Leading Particulars
Table 5 lists the physical and equipment specifications for the HGA-7001. Environmental specifications
are also included in this table.
Table 5: Equipment Specifications (Sheet 1 of 3)
Characteristic Specification
ARINC CHARACTERISTICS ARINC CHARACTERISTIC 781-1, MARK 3 AVIATION SATELLITE
COMMUNICATION SYSTEMS, Published: November 22, 2006
RTCA DOCUMENTS RTCA/DO-210D, MINIMUM OPERATIONAL PERFORMANCE
STANDARDS FOR GEOSYNCHRONOUS ORBIT AERONAUTICAL
MOBILE SATELLITE SERVICES (AMSS) AVIONICS, April 19, 2000;
Change 1 to RTCA/DO-210D, December 14, 2000;
Change 2 to RTCA/DO-210D, November 28, 2001;
Change 3 to RTCA/DO-210D, September 19, 2006
RTCA/DO160E, Environmental Conditions and Test Procedures for
Airborne Equipment, December 9, 2004
ENVIRONMENTAL CATEGORY
Temperature and altitude DO-160E Category E1
Operating temperature –55 C to +70 C
(–67 °F to +158 F)
Maximum operating altitude 21 000 meters
(70 000 feet)
In flight Loss of Cooling DO-160E Category X
Temperature variation DO-160E Category A
Humidity DO-160E Category B
Shock DO-160E Category E
Vibration DO-160E Category [U(G),R(C,C1),R(E,E1),H(R),S(LMY)]
Explosion proofness DO-160E Category E
Waterproofness DO-160E Category RS
Fluids susceptibility DO-160E Category F
Sand and dust DO-160E Category S
Fungus resistance DO-160E Category F
Salt spray DO-160E Category S

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Table 6: Equipment Specifications (Sheet 2 of 3)
Characteristic Specification
Magnetic effect DO-160E Category Z
Power input (28V) DO-160E Category A(WF)X
Voltage spike DO-160E Category A
Audio frequency conducted
susceptibility
DO-160E Category K(WF)
Induced signal susceptibility DO-160E Category CW
RF susceptibility DO-160E Category (RW)(RY)
Emission of radio frequency energy DO-160E Category H
Lightning-induced transient DO-160E Category A3J44
Lightning direct effects DO-160E Category 1A2A
Icing DO-160E Category AC
Electrostatic discharge DO-160E Category A
Fire, Flammability DO-160E Category X
DO-160E Qualification String [E1]XABE[U(G),R(C,C1),R(E,E1),H(R),S(LMY)]
E[RS]FSFSZ[A(WF)X]A[K(WF)][CW][(RW)(RY)]
H[A3J44][1A2A][AC]AX
RF CHARACTERISTICS
Operating Band: Receive
Transmit
1525 to 1559 MHz
1626.5 to 1660.5 MHz
Service Coverage Seamless coverage compliant to Inmarsat SDM
Gain 12 to 16 dBiC over 90% of the Inmarsat hemisphere
G/T ≥–13 dB/K (290 K antenna and subsystem) under all
transmitter operating conditions
EIRP 16 dBW minimum
Axial ratio < 6 dB, can be greater when compensated by excess
antenna gain
Discrimination < 13 dB for satellites spaced 45° in longitude from
desired satellite

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Table 7: Equipment Specifications (Sheet 3 of 3)
Characteristic Specification
Beam switching < 50 microseconds between adjacent beams
Phase discontinuity < 12° for 99% of adjacent beam combinations
Carrier to multipath < 13 dB at 5° elevation < 18 dB at 20° elevation
Maximum input power 80 Watts average
Polarization Right-hand circular
Impedance 50 Ohms
VSWR < 2.0:1 transmit and receive
ELECTRICAL
Power consumption < 12 Watts
ELECTRICAL INTERFACE
Control and BITE ARINC 781
MECHANICAL
Weight 9.3 kg (21 lbs) Max
Size [L x W x H] 1050 mm x 299 mm x 51.6 mm
(41.34” x 11.77” x 2.03”)
2.3 Equipment Description
The HGA-7001 is powered with 115 V AC or 28 V DC (not qualified) aircraft power. The communications
interface between the HGA-7001 and the SDU is through an ARINC 429 protocol.
2.3.1 Mechanical Description
The HGA-7001 High Gain Antenna consists of an aluminium baseplate housing a 34 segment
radiating element array, a power supply, antenna control/driver assembly, and an integrated beam
steering unit. The internal components are protected by a composite radome bonded to the
baseplate. The antenna must always be mounted to the aircraft via a mounting / adaptor plate
which is manufactured for a specific aircraft and/or fuselage diameter.
Electrical connection to the antenna is made through a MIL-C-38999 13-pin connector. The RF
connection is via a female TNC connector. For electrical bonding a ground stud or threaded hole
may be provided (dependent on aircraft configuration). The electrical connections are accessible
at the rear of the antenna via a removable Tail Cap.
Figure 2 shows the top side of the antenna with the eight sealing caps (1) removed and the Tail
Cap (2) attached.

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Figure 2: Top Side of Antenna
2.3.2 Electrical Description
The HGA-7001 is an ARINC 781 compliant low-profile, electronically steered SATCOM antenna,
using patented phased-array beam forming technology. It performs both transmit and receive
functions. The HGA-7001 contains an integrated BSU that receives commands in the ARINC 429
format.
A multi-pin connector is provided in the connector compartment for direct connection to aircraft
power, the DLNA and the SDU interface cable.
2.3.3 System Interconnection
Refer to Figure 3 and Table 8 for pin assignments of the multi-pin connector and the HGA-7001
Wiring Diagram for system interconnections. Refer to Figure 4 for a diagram of antenna
connectors.
(1) RF Interface (Female TNC connector)
The suggested mating connector is dependent on the type of low loss cable used. Low loss
cables with different diameters may require different connectors. The connector and cable
should be of low PIM specification, as recommended in ARINC 781. Contact the Supplier for
information on availability of a PIM free cable for SwiftBroadband use.
(2) Power and Data Interface (Multi-Pin Connector)
The multi-pin connector consists of a 13-35 insert of the MIL-C-38999 Series III family in a
hermetic box mount, part number D38999/21YC35PN. Suggested mating connector is
D38999/26SC35SN or equivalent.
Figure 3: Multi-pin Connector Pin Numbers

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Table 8: Connector Pin Assignments
Pin
Number Signal Description
1 +28 VDC Aircraft DC Power
2 28 VDC Return Aircraft DC Power
3 Antenna BITE A ARINC 429 from antenna
4 Antenna BITE Shield Shield for ARINC 429
5 Antenna BITE B ARINC 429 from antenna
6 Antenna Control A ARINC 429 to antenna
7 Antenna Control Shield Shield for ARINC 429
8 Antenna Control B ARINC 429 to antenna
9 DLNA BITE BITE from DLNA
10 DLNA Shield Shield/ RTN for DLNA
11 DLNA CTL DLNA on/off control from antenna
12 Serial Shield Serial Shield/GND
13 NC
14 NC
15 NC
16 NC
17 NC
18 115 VAC HOT Aircraft AC Power
19 115 VAC COLD Aircraft AC Power
20 NC
21 NC
22 Chassis Ground Chassis Ground

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(3) HGA to DLNA RF Interconnect Electrical Requirements:
(a) The combined loss of the RF cable between the DLNA and the antenna should be 0.3 dB
or less as recommended by ARINC 781. For some installations this may be difficult if the
separation between the DLNA and the antenna is too large due to practical mounting
requirements. In such cases it may be possible to increase this loss and still meet the
coverage requirements depending on other system parameters that influence the RF
path, i.e. DLNA noise figure, DLNA gain, HPA power output and path loss between the
HPA and the antenna. These cases should be referred to the Supplier for assessment.
(b) Cables and connectors must satisfy the ARINC 781 intermodulation requirements and it
is advisable that they are supplied with documentation confirming this. Contact the
Supplier for support in this regard.
(4) HGA to DLNA Multi-Pin Interconnect Electrical Requirements
(a) The total resistance of the CONTROL wire and DLNA Screen must be < 8 Ω.
(b) The resistance of the BITE wire must be < 1.0 kΩ.
(c) It is recommended the BITE/CONTROL wires be screened and grounded on both sides.
(5) HGA to Aircraft Power Interconnect Electrical Requirements
CAUTION: THE ANTENNA WILL BE DAMAGED BY THE APPLICATION OF 115 VAC AT 50-60
HZ. THE HGA-7001 OPERATES FROM 115 VAC VARIABLE FREQUENCY (280 TO
800 Hz) OR 28 VDC ONLY – DC INPUT HAS NOT BEEN FORMALLY QUALIFIED
NOTE: THE ANTENNA NEEDS ONLY ONE POWER SOURCE (EITHER AC OR DC) TO BE
CONNECTED.
(a) AC SUPPLY WIRING (280 Hz to 800 Hz)
1) The volt drop must be less than 19 VAC (i.e. the supply voltage must not drop
below 96 VAC) at the CONTROL and DATA connector under aircraft emergency
conditions.
2) The maximum AC current drawn by the antenna at 96 VAC is 200 mA.
(b) DC SUPPLY WIRING
1) The volt drop must be less than 10.5 VDC (i.e. the supply voltage must not drop
below 17.5 VDC) at the CONTROL and DATA connector under aircraft emergency
conditions.
2) The maximum DC current drawn by the antenna at 17.5 VDC is 1.14 A.

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Figure 4: HGA-7001 High Gain Antenna Connector Locations (positions relative to the hole in fuselage and
the hole size are typical)

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2.3.4 Operation
The system receives antenna status and pointing commands via an ARINC 429 interface from a
SDU. The system reports antenna status, including the results of Built-In-Test (BIT) to the SDU
over the same bi-directional Interface B (Figure 5).
(1) The HGA connects to the Diplexer/Low Noise Amplifier (DLNA) via interface A.
Aeronautical High Gain Antenna Unit
Interface B
Interface A
DLNA
SDU
Transmit and receive
path for
L-band RF
HPA
Transmit path for
L-band RF
Receive path for
L-band RF
Interface C
Satellite link
ARINC 429
Figure 5: HGA Interfaces
2.3.5 BIT/BITE
Faulty units are identified via the various levels of internal BITE that provide error and warning
codes. These codes can be accessed through the SATCOM system. In the event of a fault, the
SDU will receive an ARINC Maintenance Word, which is a map of errors and/or warnings received.
Faulty units must be returned to the Supplier.

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3. STORAGE AND TRANSPORTATION
3.1 Introduction
This section provides information regarding the HGA-7001 storage and transportation, with special
reference to temperature and relative humidity.
3.2 Storage
Whenever the HGA-7001 is being stored, it is advised the unit is placed inside its shipping container. The
container must be stored in a dry area (< 50% RH) while the temperature must not exceed –55 °C (–67
°F) or +85 °C (+185 °F).
3.3 Transportation
The HGA-7001 is highly robust; however, it is recommended that standard ESD handling precautions be
observed at all times.
The original transport packaging is reusable and it is recommended that this be retained for storage or
return purposes.