Hughes 9300 Series User manual

Hughes 9300 Series Mobile Satellite
Terminal
Installation Guide
Document No. 1038494-0001
Revision D
Hughes Network Systems
9605 Scranton Road, Suite 500
San Diego, California 92121
Copyright © 2009-2010 Hughes Network Systems, LLC
All rights reserved. This publication and its contents are proprietary to Hughes Network
Systems, LLC. No part of this publication may be reproduced in any form or by any means
without the written permission of Hughes Network Systems, LLC, 11717 Exploration Lane,
Germantown, Maryland 20876.
Hughes Network Systems, LLC has made every effort to ensure the correctness and
completeness of the material in this document. Hughes Network Systems, LLC shall not be
liable for errors contained herein. The information in this document is subject to change
without notice. Hughes Network Systems, LLC makes no warranty of any kind with regard to
this material, including, but not limited to, the implied warranties of merchantability and
fitness for a particular purpose.
Trademarks
Hughes, HughesNet, Hughes Network Systems, and SPACEWAY are trademarks of Hughes
Network Systems, LLC. All other trademarks are the property of their respective owners.
INMARSAT is a trademark of the International Mobile Satellite Organization. The
Inmarsat LOGO and the trademark BGAN are trademarks of Inmarsat (IP) Company
limited. All trademarks are licensed to Inmarsat Limited.

Hughes 9300 Series Installation Guide
Contents
Hughes 9300 Series Mobile Satellite Terminal .................................................................. 1
Installation Guide................................................................................................................ 1
Introduction......................................................................................................................... 4
Indoor Unit (IDU)............................................................................................................... 5
Power Port....................................................................................................................... 6
Ethernet Port ................................................................................................................... 6
RJ 45 Ethernet Port with Power over Ethernet (PoE)..................................................... 6
ISDN Port........................................................................................................................ 7
RJ11 Ports ....................................................................................................................... 7
Antenna Port ................................................................................................................... 7
USB Port ......................................................................................................................... 8
WLAN Port..................................................................................................................... 8
SIM Card......................................................................................................................... 8
System Power Requirements .............................................................................................. 9
Fuse................................................................................................................................. 9
Power Cable.................................................................................................................... 9
Standard Cable Connections............................................................................................... 9
Ignition Sense (White Wire) ......................................................................................... 10
Chassis Grounding........................................................................................................ 10
Basic Installation Procedure ............................................................................................. 11
Vehicular Installation........................................................................................................ 11
Installation – General.................................................................................................... 11
Common IDU Mounting Information........................................................................... 12
The Antenna Outdoor Unit (ODU)................................................................................... 13
Antenna Cable Lengths and Types ............................................................................... 14
Installing the Antenna................................................................................................... 14
Land Mobile Antenna ....................................................................................................... 16
Magnetic Mounting (Optional)..................................................................................... 16
Magnetic Mount Installation......................................................................................... 16
Dismounting the Magnetically Mounted Antenna........................................................ 17
Permanent Mount Installation....................................................................................... 17
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Hughes 9300 Series Installation Guide
TableofFigures
Figure 1 – IDU Common IDU (left), Class 10 ODU (middle), and Class 11 (right) ......... 4
Figure 2 – Indoor Unit (IDU).............................................................................................. 5
Figure 3 – Power Port Pin Out............................................................................................ 6
Figure 4 – Ethernet Port Pin Out......................................................................................... 6
Figure 5 – ISDN Port Pin Out............................................................................................. 7
Figure 6 – RJ11 Port Pin Out.............................................................................................. 7
Figure 7 – Inserting SIM Card in the SIM Card Holder..................................................... 8
Figure 8 – System Power Requirements............................................................................. 9
Figure 9 – Power Cable Pin Out ......................................................................................... 9
Figure 10 – Grounding Nut............................................................................................... 10
Figure 11 – Common Indoor Unit Mounting Dimensions................................................ 12
Figure 12 – Class 10 Antenna ODU Ø477 mm X 153 mm Height .................................. 13
Figure 13 – C11 Antenna ODU Ø252 mm x 119 mm Height .......................................... 14
Figure 14 – C10 Antenna with Magnetic Mount Component Parts ................................. 16
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Hughes 9300 Series Installation Guide
Introduction
This guide provides assistance to personnel installing the Hughes 9300 Series mobile
satellite terminal into a vehicle.
Installation Warning
This product is to be installed by Authorized Service Personnel.
Note: Damages resulting in the failure to conform to the instructions found herein, as
well as standard installation practices, will be the responsibility of the installer.
Hughes 9300 Series Mobile Satellite Terminals
The mobile satellite terminals are composed of four core component parts: the
transceiver or indoor unit (IDU), the antenna outdoor unit (ODU), the power
connector/cable, and an 8 meter RF cable.
Figure 1 – IDU Common IDU (left), Class 10 ODU (middle), and Class 11 (right)
The Hughes IDU multiple interfaces that various terminal equipment (TE) devices such
as laptops, PDAs, phones, etc., can connect to are Ethernet, ISDN, USB, POTS (RJ11),
and wireless LAN (WLAN).
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Hughes 9300 Series Installation Guide
Indoor Unit (IDU)
The IDU provides all of the TE interfaces, plus the interface for the antenna (ODU), and
manages the communications over the Inmarsat BGAN network. Communication to the
antenna (ODU) is provided by the RF cable from the IDU.
Figure 2 – Indoor Unit (IDU)
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Hughes 9300 Series Installation Guide
The IDU is equipped with the following ports:
Power Port
The power port is the connection from the power supply (vehicle battery or some other
12 or 24 VDC power source) to the IDU. The power cable has a +V power line, an
ignition sense line, and a –V power line.
Line Type Pin Number
+V Power Line 1
Ignition Sense 2
-V Power Line 3
Figure 3 – Power Port Pinout
Ethernet Port
RJ 45 Ethernet Port with Power over Ethernet (PoE)
There is one RJ45 port with Power over Ethernet (PoE) on the IDU. The port supplies
standard PoE according to the IEEE 802.3af standard (48 VDC up to 15.4 W) and
10BaseT Ethernet. The pin out of the port supports a direct straight-through connection to
a PC with a standard Ethernet cable. The PC will be supplied with a dynamic local IP
address using a standard DHCP exchange. Figure 4 shows the pinout of the Ethernet
connector.
Pin
1 RX+
2 RX-
3 TX+
4 +48V
5 +48V
6 TX-
7 -48V
8 -48V
Figure 4 – Ethernet Port Pinout
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Hughes 9300 Series Installation Guide
ISDN Port
There is one ISDN port on the IDU. It provides 4 kbps voice, 3.1 kHz audio, and 64 kbps
data communication. The following chart depicts the pinout of the ISDN connector.
Pin
1 NC
2 NC
3 ISDN RX+(+40V)
4 ISDN TX+(-40V)
5 ISDN TX-(-40V)
6 ISDN RX-(+40V)
7 NC
8 NC
Figure 5 – ISDN Port Pinout
RJ11 Ports
There are two RJ11 ports on the IDU: FAX is for 3.1k fax calls, and TEL for 4 kbps
speech calls. The following chart depicts the pinout of the RJ11 connectors.
Pin
1 NC
2 NC
3 Tip (+V)
4 Ring (-V)
5 NC
6 NC
Figure 6 – RJ11 Port Pinout
Antenna Port
The antenna port is a 50Ωfemale TNC connector. This line carries the L-band RF, ASK
signaling, and DC power (42 VDC) for the antenna.
WARNING: The antenna cable carries DC power. Do not connect or disconnect
the antenna cable while the unit is powered on.
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Hughes 9300 Series Installation Guide
USB Port
There is one V1.1 USB client port on the IDU. The IDU has a USB Standard-B
receptacle. The USB device appears as an Ethernet device to the user computer and
requires a proprietary USB driver available from the Hughes or Inmarsat Web sites.
WLAN Port
The WLAN port on the IDU is a reverse polarity SMA jack. The supplied antenna is a
2.4 GHz 3dBi “Rubber Duck” antenna with RP-SMA plug connector, part number
HG2403RD-RSF.
To prevent blocking or attenuation of the WLAN signal, the IDU should be installed such
that there is no metal blocking the radio path to the user’s device.
SIM Card
The 9350 requires the installation of an Inmarsat SIM. Insert the SIM (supplied by the
dealer) into the SIM card holder with the metal contacts facing down. Reinsert the holder
and SIM card as shown in Figure 7.
Figure 7 – Inserting SIM Card in the SIM Card Holder
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Hughes 9300 Series Installation Guide
System Power Requirements
There is one power connection on the IDU. This must be connected to a 12 or 24 VDC
power supply.
Power requirements and consumption are as follows:
Voltage Input Minimum 10 V
Voltage Input Maximum 31 V
Total Current for ODU and IDU (max.) 6 A
Required Fuse >=10 A
Figure 8 – System Power Requirements
Fuse
The fuse is a 10 A, 5 mm by 20 mm cartridge. The installed part is from Littelfuse, part
number 0234010. To replace the fuse, turn the fuse holder anticlockwise with a flat head
screw driver and the holder will pop out.
Power Cable
The power cable uses an Amp 1-178288-3 connector, and the pinout is shown in
Figure 9.
Color Function
Red DC +
White Ignition Sense
Black DC -
Figure 9 – Power Cable Pinout
The optional accessory car adapter power cable includes a car adapter plug with a
10 A fuse and the ignition sense wire is connected to the positive power wire in the plug.
Standard Cable Connections
In addition to the DC power connection, an ignition sense connection must be made.
This is done using the three-wire power cable. In the case of a vehicle installation, the
power source is typically the vehicle battery. Cables should be routed appropriately, and
cable ties and clamps should be used as required to ensure that vibration and/or rubbing
of the cables does not occur.
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Hughes 9300 Series Installation Guide
Ignition Sense (White Wire)
Route and connect the white wire (ignition sense) to a switched 12 or 24 VDC source,
such as accessory line or fuse block. Extended use of ignition sense in the accessory
position (ACC) by the end user may lead to a discharged car battery.
Note: Ensure that the connection is a switched source, OFF when ignition is off or in
start and ON only when the ignition switch is in the ACCESSORIES or RUN position.
If using the car adapter plug, the ignition sense wire is already connected to the positive
power wire in the plug.
Chassis Grounding
The unit includes an isolating power supply. To ground the IDU in case the grounding
provided by mounting bracket is insufficient, connect a grounding wire from the chassis
grounding wing nut to the vehicle chassis.
Figure 10 – Grounding Nut
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Hughes 9300 Series Installation Guide
Basic Installation Procedure
While the installation of the Hughes 9300 Series mobile satellite terminal is
straightforward, it is essential that the installation be done correctly.
The basic installation procedure is as follows:
1. Decide where you are going to install the antenna and IDU.
2. Ensure that the IDU is located inside the vehicle and attached to something
structurally solid. Loose mounts that vibrate will degrade performance.
3. Determine the cable length required for the power installation.
4. Perform the installation of the antenna and IDU.
5. Connect the antenna via the three magnetic mounts to the vehicle’s roof or
permanently mount using screws/bolts.
6. Connect the RF cable to both the IDU and antenna TNC connectors.
7. Connect the power to the IDU.
8. Properly ground the IDU.
9. Power up the IDU/antenna.
Vehicular Installation
Installation – General
1. Whenever routing cable through holes drilled in metal or through bulkheads, use
grommets and RTV sealant to weatherproof all holes drilled on the outside of the
vehicle.
2. Use cable ties every 30–45 cm (12"–18").
3. The IDU can be mounted in either the horizontal or vertical position.
4. The main power line must be connected to a fused 12 or 24 VDC power source.
The unit is fused, but a 10 A or greater fuse is required in the source to protect
against shorts in the cabling. If connecting to a circuit in the fuse box already in
use, ensure that the circuit can supply the extra 6 A at 12 V or 3 A at 24 V for the
unit and increase the fuse value by 10 A at 12 V or 5 A at 24 V. If using the car
adapter cable, it already includes the fuse in the adapter.
5. Route and connect the white Ignition Sense wire to a switched 12 or 24 VDC
source.
6. Ground the IDU to the vehicle via a wire connected to the IDU ground wing nut.
7. Install the IDU in a protected but ventilated area. Allow at least a 1 inch space
around all surfaces, except for the bottom surface attached to the vehicle, to
provide adequate cooling. Ensure that the location is accessible for servicing.
8. The IDU is not waterproof.
9. Always provision the wiring into the IDU with a drip loop.
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Hughes 9300 Series Installation Guide
10. With the exception of the IDU to antenna RF cable, do not route the power cable
outside the vehicle.
Common IDU Mounting Information
Note: Use care when drilling through the body of the vehicle to avoid puncturing critical
items.
Instructions for the installer:
1. Mount the terminal onto a flat surface using at least four screws (not
supplied). Use screws with a diameter between 3.5 and 4 mm. Vibration
resistant screws or lock washers should be used.
2. There are three holes/slots on either side of the base of the terminal for
mounting the screws.
Figure 11 – Common Indoor Unit Mounting Dimensions
53 mm x 253 mm x 305 mm without WLAN Antenna
133 mm x 253 mm x 305 mm with WLAN Antenna
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Hughes 9300 Series Installation Guide
The Antenna Outdoor Unit (ODU)
The antenna unit is composed of the antenna element, high power and low noise
amplifier systems, and a mechanical tracking system.
Both the Class 10 and Class 11 ODUs are two-axis antennas intended for land-mobile
use.
Connection to the ODU is made by a TNC connector. The single coaxial cable carries
L-band RX and TX, power, and tracking information.
WARNING: Only use the C10 antenna supplied with the 9300 Series Terminal.
Do not use the similar looking C10EE antenna from a Hughes 9250.
Figure 12 – Class 10 Antenna ODU Ø477 mm X 153 mm Height
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Hughes 9300 Series Installation Guide
Figure 13 – C11 Antenna ODU Ø252 mm x 119 mm Height
Antenna Cable Lengths and Types
The Hughes IDU has an automatic cable calibration feature that determines the dB loss of
the cable. The RF cable that comes standard in the terminal kit is 8 meters long. If a
longer cable is required for the installation, the end-to-end RF loss needs to be <10 dB at
1.6 GHz.
Note: The installer is responsible for choosing the proper type of cable for the length
required in order to meet the <10 dB requirement.
Installing the Antenna
WARNING: Avoid exposure to microwave radiation. Keep a minimum safe
distance of one meter (39 inches) to the side and above the antenna.
WARNING: The antenna cable carries DC power. Always power the IDU down
prior to connecting or disconnecting the antenna cable from either the antenna or the
IDU.
The antenna port is a 50Ωfemale TNC. This line carries RF, signaling, and DC power for
the antenna.
Keep a clear line-of-sight to the satellite. Preferably, avoid all obstructions within
3 meters of the antenna. Obstructions less than 15 cm (6 inches) in diameter can be
ignored beyond this distance.
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Hughes 9300 Series Installation Guide
It is important to ensure that there is a clear line-of-site to the satellite(s) in all directions.
After the terminal is operational, it is recommended that the signal strength be checked
while the vehicle is slowly driven in a 360º circle. The signal strength should not vary
significantly or be degraded in any particular direction.
Do not locate the antenna close to interfering signal sources or receivers. It is
recommended that no other antennas be located within 3 meters of the 9300 Series
antennas. If there is other equipment installed near the Hughes 9300 Series mobile
satellite terminal, it is recommended to operate all equipment simultaneously and verify
there is no cointerference.
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Hughes 9300 Series Installation Guide
Land Mobile Antenna
Magnetic Mounting (Optional)
Three magnetic mounts are provided for the antenna installation. These mounts will
withstand 100 mph wind force.
If the antenna cannot be mounted using the magnetic feet, the magnetic feet can be
removed and the mounting holes can be used to bolt the antenna onto a roof bracket
system.
Magnetic Mount Installation
The magnet mount consists of three individual high intensity magnets with rubber
coating. Each magnet has a stainless steel center bolt.
First attach the magnets to the antenna. There are three “legs” on the antenna where the
magnets are placed. Note the position of the two rubber washers just below and above
each antenna leg, the stainless steel washer above the upper rubber washer, and the
protective nut on top.
Figure 14 – C10 Antenna with Magnetic Mount Component Parts
Next, place the antenna with magnets on the roof of the car. When installing the antenna
cable, it is important to protect against moisture by using self-amalgamating or similar
tape wrapped around the coaxial connector. Also be careful with the cable run from the
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Hughes 9300 Series Installation Guide
17
antenna and secure it at short intervals. An unsupported length of cable will vibrate when
driving and could negatively affect the connection over time.
Dismounting the Magnetically Mounted Antenna
Use your hand to pry underneath the antenna near one of the magnets and lift. When one
magnet is loose, the other two easily break off.
Permanent Mount Installation
If the antenna cannot be mounted using the magnetic feet option, the three mounting
holes on the outside diameter of the antenna can be used to bolt the antenna onto a roof
bracket system. Ensure that you utilize the proper bolt size to withstand the wind loading
and vibration that the antenna will undergo for your particular application.