Flightcell Iridium User manual

Flightcell Iridium Modem
Installation manual
Document Number: MAN_MO4_002
Document Version: 1.0
2nd November 2016
www.flightcell.com

| CONTENTS |
| Flightcell Iridium Modem Installation Manual Page 2of 12|
CONTENTS
1INTRODUCTION............................................................................................................................................ 3
2FLIGHTCELL IRIDIUM MODEM SPECIFICATIONS............................................................................................ 4
3COMPONENTS REQUIRED FOR INSTALLATION ............................................................................................. 5
3.1 CONNECTORS AND FASTENERS.............................................................................................................................5
3.2 ANTENNA........................................................................................................................................................5
4INSTALLING THE FLIGHTCELL IRIDIUM MODEM............................................................................................ 6
4.1 MOUNTING THE MODEM....................................................................................................................................6
4.2 WIRING THE MODEM.........................................................................................................................................6
4.3 GUIDELINES FOR FABRICATING THE WIRING HARNESS ...............................................................................................7
4.4 GUIDELINES FOR THE ANTENNA CABLE...................................................................................................................7
5SETTING UP YOUR MODEM.......................................................................................................................... 8
5.1 CONNECTING TO THE IRIDIUM NETWORK ...............................................................................................................8
5.2 CONFIGURING YOUR DZMX TO WORK WITH THE MODEM .........................................................................................8
5.3 USING THE MODEM STANDALONE .......................................................................................................................8
5.4 CONFIGURING DATA INTERFACE ..........................................................................................................................8
5.5 INSTALLING A SIM CARD ....................................................................................................................................9
6WARRANTY AND CONTACT DETAILS .......................................................................................................... 10
LIMITED WARRANTY FOR YOUR FLIGHTCELL IRIDIUM MODEM..............................................................................................10
FLIGHTCELL INTERNATIONAL CONTACT DETAILS .................................................................................................................10
APPENDIX 1: VERSION HISTORY......................................................................................................................... 11
APPENDIX 2: WIRING AND INSTALLATION DRAWINGS ...................................................................................... 12

| Introduction |
| Flightcell Iridium Modem Installation Manual Page 3of 12|
1Introduction
The Flightcell Iridium Modem is a robust modem designed specifically for installation with a DZMx or as
a standalone modem. The modem supports Iridium voice, SMS, SBD and data services.
If the modem is installed with a DZMx, the DZMx controls the modem and provides audio integration
into the aircraft ICS/audio panel. The modem must be installed with an appropriate external Iridium
antenna. Several antenna options are available from Flightcell International.

| Flightcell Iridium Modem Specifications |
| Flightcell Iridium Modem Installation Manual Page 4of 12|
2Flightcell Iridium Modem Specifications
Flightcell part number
MOP_00010
Material
Faceplate and backplate –diecast Type 380 Aluminium
with Alodine Chromate finish
Extrusion –6063 Aluminium with clear anodized finish
Input voltage
12-32 V DC
Power supply current
Maximum current –500mA @ 28V
RF Frequency Range
1616MHz –1624.5MHz
Average RF TX Power
During a TX slot (max)
7W
During a frame (typ.)
0.6W
RF RX Sensitivity
-118dBm
Max cable loss1
3dB
Max Antenna gain
3dBi
MIC audio
Input
Fully Differential –50mVrms to 1Vrms
Nominal 775mVrms
Input impedance
600Ω
SPK audio
Output
Fully differential –Up to 1Vrms into 150 Ω
Nominal 775mVrms
Output impedance
600Ω
Data connection
Switchable RS-485/RS-232
For RS-232 - RTS/CTS Flow control only.
USB 2.0
Weight
240 grams
8.5 oz
Dimensions
Width
62mm
2.44”
Height
33.9mm
1.35”
Depth
144mm
5.67”
Main connector
DA-15F
Antenna connector
TNC
Certification
Designed to meet DO160G Sections: 4 (Temp), 6
(Humidity), 7 (Shock/Crash Safety), 8 (Vibration) 15
(Mag), 20 RF Susceptibility), 21 (EMI), 25 (ESD)
1. The total implementation loss for antenna, connectors, cable and any other RF components between the modem and the
antenna should not exceed 3dB.
Table 1. Flightcell Iridium Modem specification

| Components required for installation |
| Flightcell Iridium Modem Installation Manual Page 5of 12|
3Components required for installation
3.1 Connectors and fasteners
The modem is connected to a wiring harness which is in turn connected to a Flightcell DZM (or a
PC/embedded device).
Table 2 shows the terminating connectors and fasteners used with the modem.
Connectors
Main connector
M24308/4-2F (DA-15 Male)
Antenna connector
TNC
Fasteners
4 x M4 screws or bolts sized to fit mounting surface
Table 2. Connectors and fasteners required for your modem installation
3.2 Antenna
The Flightcell Iridium Modem requires an antenna installed on the outside of the fuselage, or in a
location with a clear view of the sky (for standalone installations).
Table 3 shows recommended Flightcell antennas. These can be obtained from Flightcell International or
your authorised Flightcell dealer.
Antenna
Suitable for
part number
Dual Flat Antenna L1 GPS/Iridium BNC/TNC White TSO Cert
All aircraft - DZMx
ANP_00012
Single Flat Antenna Iridium TNC
Stand alone
ANP_00010
Table 3. Recommended Flightcell Iridium antennas

| Installing the Flightcell Iridium modem |
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4Installing the Flightcell Iridium modem
4.1 Mounting the modem
The modem should ideally be located close to the DZMx (if installed with DZMx), preferably where it is
reasonably readily accessible to enable easy access to the SIM card.
Appendix 2 includes drawing references for a dimensioned drawing of the modem, showing mounting
details.
4.2 Wiring the modem
The data and audio connections should be made as per the wiring diagrams referenced in Appendix 2.
Modem pin
Function
1
DC in
Power
2
Audio from Sat Lo
Output
3
Audio to Sat Lo
Input
4
Sat Data GND
Signal GND
5
RS-232 RTS / RS-485 RX-
Input
6
RS-232 CTS / RS-485 TX-
Output
7
USB GND
Signal GND
8
USB D-
I/O
9
Power GND
Power GND
10
Audio from Sat HI
Output
11
Audio to Sat HI
Input
12
USB VBUS / GPI
Input
13
RS-232 RXD / RS-485 RX+
Input
14
RS-232 TXD / RS-485 TX+
Output
15
USB D+
I/O

| Installing the Flightcell Iridium modem |
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4.3 Guidelines for fabricating the wiring harness
For aviation applications, all wiring should be carried out with aviation specification fireproof cable.
Screened cable should be used where indicated in the wiring diagrams. Where cable screen connections
are not explicitly shown, they should be left unterminated.
The following minimum wiring specification is recommended:
Power supply - 22 AWG (0.325mm2)
Other cabling - 24 AWG (0.205mm2).
4.4 Guidelines for the antenna cable
The antenna and associated cabling should have a nominal impedance of 50Ω with a maximum
attenuation of 3dB over the cable run.
The antenna cable run length and intended frequency bands of operation should be checked before the
antenna cable type is selected to ensure the above requirements are met.

| Setting up your modem |
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5Setting up your modem
5.1 Connecting to the Iridium network
The Flightcell Iridium modem operates on the Iridium satellite network. To enable connectivity an
Iridium SIM card provisioned for the desired services is required. Please contact your preferred Iridium
service provider for details.
5.2 Configuring your DZMx to work with the modem
Your DZMx will need to be configured to use the Flightcell Iridium Modem. Instructions for configuring a
DZMx to work with the modem can be found in the operators’ manuals for DZMx products. These
manuals are provided on a USB memory device supplied with your DZMx, or available from the Flightcell
support page at http://www.flightcell.com/support.aspx.
5.3 Using the Modem Standalone
If the modem is to be used in standalone mode it will need to be connected to a PC (or embedded
device) which can control the internal Iridium transceiver directly. The Iridium modem uses the Iridium
9523 transceiver, contact Flightcell for details of the Iridium 9523 AT interface.
5.4 Configuring Data Interface
The Flightcell Iridium modem can be set to use either an RS-232 or RS-485 data interface. This selection
can be made using the switch which is accessible under the SIM card holder. The switch is sampled on
start-up and should be in the left position for RS-232 and the right position for RS-485.
Figure 1 SIM card slot showing data format selection switch.

| Setting up your modem |
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5.5 Installing a SIM card
The Flightcell Iridium Modem will not register on a network until a valid SIM card with a current account
is installed.
The DZMx will provide an error message if either there is no SIM card installed, or there is an invalid
SIM installed. Please see the Operators’ manual for your DZMx for more details on error messages.
If the modem is standalone, the connected device will need to interrogate the modem via the AT
interface to determine the SIM / network registration status.
To install the SIM card:
-Remove the rubber plug in the end of the modem;
-Insert the SIM card in the slot and press till it clicks into place;
-Reinsert the rubber plug.
The correct orientation of the SIM card is with the gold contacts down, and with the end of the card
with the diagonal cutout inserted first. The SIM card will not fully insert in the wrong orientation.

| Warranty and contact details |
| Flightcell Iridium Modem Installation Manual Page 10 of 12|
6Warranty and contact details
Limited warranty for your Flightcell Iridium Modem
Flightcell International Ltd's quality products are proudly designed and manufactured to the highest
standards in New Zealand.
Your Flightcell Iridium Modem is warranted for one year from date of sale.
The warranty is void if any labels are removed or if it is determined that your modem has been:
Connected to a power supply delivering more than 32 Volts;
Connected with reverse polarity;
Installed in direct contravention to the guidelines outlined in the installation manual;
Physically damaged, or a fault has occurred due to the product being used beyond what is
considered normal use, causing unusual deterioration of the product.
If the product is deemed to be faulty or in need of repair, please contact Flightcell International Ltd to
obtain a Returned Materials Authorization or download from http://www.flightcell.com/support.aspx.
Flightcell International contact details
Flightcell International Ltd
PO Box 1481
98 Vickerman Street
Nelson 7040
New Zealand
Phone [phone]
Email [email protected]

| Appendix 1: Version history |
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Appendix 1: Version history
Version
Date
Author
Change Note Number
Description
1.0
2nd November 2016
J. Glasgow
FCN0708
Initial release.

| Appendix 2: Wiring and installation drawings |
| Flightcell Iridium Modem Installation Manual Page 12 of 12|
Appendix 2: Wiring and installation drawings
The following references list the Iridium modems wiring diagrams and mechanical drawings which are
available on the Flightcell website: http://www.flightcell.com/support.aspx
Interconnect drawings for DZMx & Standalone installations:
WRL_MO4_001 - DZMx ICD
WRL_MO4_001 - Standalone ICD
Mechanical drawings:
DRW_MO4_001 - Mechanical Outline Drawing