Hughes IP Voyager User manual

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permission of Hughes Network Systems, LLC, 11717 Exploration Lane, Germantown, Maryland
20876.
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of the material in this document. Hughes Network Systems, LLC shall not be liable for errors
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•Contents
iii
Contents
Understanding safety alert messages ..................................................................................... vii
Messages concerning personal injury ......................................................................................................vii
Safety symbols .......................................................................................................................... vii
Chapter 1 Introduction.........................................................................................................9
Hughes mobile satellite terminals..............................................................................................................9
Below Deck Unit (BDU) ......................................................................................................................... 10
Physical dimensions............................................................................................................................. 10
Power port............................................................................................................................................ 11
Table 2. Power port pin out................................................................................................................11
Four RJ-45 Ethernet with Power over Ethernet (PoE) ports................................................................11
WLAN port .......................................................................................................................................... 12
Antenna port......................................................................................................................................... 12
SIM card...............................................................................................................................................12
System power requirements .................................................................................................................13
Table 4. System power requirements................................................................................................. 13
Fuse ......................................................................................................................................................13
Chapter 2 Below Deck Unit (BDU) Install........................................................................15
Basic BDU installation procedure............................................................................................................15
Installation notes ......................................................................................................................................15
BDU mounting information.....................................................................................................................16
Chapter 3 Above Deck Unit (ADU) Install .......................................................................17
Physical dimensions.................................................................................................................................17
Antenna cable lengths and types..............................................................................................................17
Antenna Installation .................................................................................................................................17
Antenna Mounting ...................................................................................................................................19
Antenna Magnetic Mounting ................................................................................................................... 20
Antenna Vibration....................................................................................................................................21

•Figures
v
Figures
Figure 1-1. BDU (left) and ADU (right) Land Mobile antenna............................................................... 9
Figure 1-2. Below Decks Unit (BDU) ................................................................................................... 10
Figure 1-3. Fitting the SIM card Cover.................................................................................................. 13
Figure 2-1. BDU - mounting dimensions in mm. .................................................................................. 16
Figure 2-2 BDU Wiring Diagram ......................................................................................................... 16
Figure 3-1. ADU – Land Mobile Antenna.............................................................................................17
Tables
Table 1. Land Mobile Kit Parts.............................................................................................................. 10
Table 2. Power port pin out.................................................................................................................... 11
Table 3. RJ-45 Ethernet port pinout....................................................................................................... 11
Table 4. System power requirements..................................................................................................... 13

•Safety
vii
Understanding safety alert messages
Safety alert messages call attention to potential safety hazards and tell you how to
avoid them. These messages are identified by the signal words WARNING or
CAUTION, as illustrated below. To avoid possible property damage, personal injury, or
in some cases possible death, read and comply with all safety alert messages.
Messages concerning
personal injury
The signal words WARNING and CAUTION indicate hazards that could result in
personal injury or in some cases death, as explained below. Each of these signal
words indicates the severity of the potential hazard.
WARNING indicates a potentially hazardous situation,
which if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation,
which if not avoided, could result in minor or moderate
injury.
Safety symbols
The generic safety alert symbol calls attention to a potential personal injury
hazard. It appears next to the WARNING and CAUTION signal words as part of the
signal word label. Other symbols may appear next to WARNING or CAUTION to
indicate a specific type of hazard (for example, fire or electric shock).

•Package materials
9
Chapter 1 Introduction
The purpose of this guide is to provide assistance to personnel installing the Thuraya
IP Voyager mobile satellite terminal into a vehicle.
This terminal must 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.
Thuraya IP Voyager satellite terminals
The Thuraya IP Voyager satellite terminal is composed of four core component parts:
the transceiver or Below Deck Unit (BDU), the antenna or Above Deck Unit (ADU), the
power connector/cable,and an RF cable.
Figure 1-1. BDU (left) and ADU (right) Land Mobile antenna

10
•The Below Deck Unit BDU
The Thuraya Mobility (Land Mobile) kit is shipped with the following contents:
Model Hughes part
number
Description
Thuraya IP Voyager
(9105) Land Mobile kit
3500462-0004 Radio, Thuraya IP Voyager (kit)
9506197-0001 WLAN antenna (2.4 GHz, 3 dB)
3500472-0001 Power cable with 3-pin connector
3500860-0001 SIM cover plate
9504275-0008 15 Amp, fast blow, ATO blade fuse (2 pieces)
PDF Install Manual
PDF User Manual
3500855-0001 Land Mobile Antenna Type HN221
TNC-TNC/6m RF coax cable TNC-TNC (6 meter)
Table 1. Land Mobile Kit Parts
Below Deck Unit (BDU)
The BDU provides all of the TE interfaces, plus the interface for the antenna (ADU)
and manages the communications over the Thuraya network. Communication to the
ADU is provided by a single RF cable from the BDU.
Physical dimensions
BDU:Size: 46mm x 281mm x 233mm
Weight: 2.2kg
Figure 1-2. Below Decks Unit (BDU)

•Package materials
11
Power port
The power port is the connection from the power supply (vehicle battery or some other
12 or 24Vdc power source) to the BDU.The power cable has a positive DC power line,
aRemote Switch line and a negative DC power line.
Line type Pin number
V+ DC power line 1
Remote Switch 2
V- DC power line 3
Table 2. Power port pin out
Four RJ-45 Ethernet with Power over Ethernet (PoE) ports
There are four RJ-45 ports with Power over Ethernet (PoE) on the BDU. The ports
supply standard PoE according to the IEEE 802.3af standard and 10/100BaseT
Ethernet. The pinout of the ports supports a direct straight-through connection to a PC
with a standard Ethernet cable. Table 3shows the pinout of the Ethernet connector.
Pin
1RX+
2RX-
3TX+
4NC
5NC
6TX-
7NC
8NC
Table 3. RJ-45 Ethernet port pinout
Note: The +48V and -48V are supplied over the TX, RX pairs.
They are only active when an 802.3af compliant device is
plugged in. The other pairs (4, 5, 7, and 8) are unused.
The total power supplied by the PoE is limited to 30W maximum for 12V installations
and 60W maximum for 24V installations. The BDU automatically detects the class of
the device plugged in and will apply power so that the total cannot exceed these limits.
If the user attempts to connect a combination of devices that require more than this,
the BDU will not power any devices that would cause the limit to be exceeded.
Note: Class 4 (802.3at) PD devices are not supported.

12
•The Below Deck Unit BDU
WLAN port
The WLAN port on the BDU is a reverse polarity SMA jack. The supplied antenna is a
2.4 GHz 3dBi “rubber duck” antenna with RP-SMA plug connector supplied.
To prevent blocking or attenuation of the WLAN signal, the BDU should be installed
such that there is no metal blocking the radio path to the user’s device.
Antenna port
The ADU (antenna)connectsto the 50 Ohm female TNC connector antenna port on the
BDU by anRF cable which carries L-band RF; signaling, &DC power (42Vdc) for the
antenna.
The antenna cable carries DC power; do not connect or disconnect the antenna cable
while the unit is powered on.
ONLY use the Thuraya Land Mobile Antenna Type HN221 with this BDU –use of other
antennas may damage the BDU and Antenna and shall void the warranty.
SIM card
SIM Card: The BDU requires a Thuraya SIM to be installed. Insert the SIM (supplied
by your service provider) into the SIM card holder with the metal contacts facing down.
ASIM card cover is supplied as an accessory with the BDU and may be utilized if
desired. Use this to prevent accidental removal of the SIM card or if additional security
is required. Note: the following tool (not supplied) is required to fit the SIM Card
Cover: Screwdriver, Torx 8 (for a metric M2.5 screw). See Figure 1-3 for attaching the
SIM card cover.

•Package materials
13
Figure 1-3. Fitting the SIM card Cover
System power requirements
There is one power connection on the BDU.This must be connected to a 12 or 24Vdc
supply. Power requirements and consumption are as follows:
Voltage Input Minimum 10V
Voltage Input Maximum 32V
Total Current for ADU and BDU
(Max. @12V)
12A
Required Fuse 15A
Table 4. System power requirements
Fuse
The fuse is a 15 Amp, fast blow, ATO blade fuse. The installed part is from Littelfuse,
part number 0287015. To replace the fuse, pull fuse out of fuse holder (pliers may be
needed to grip fuse) and press new fuse into fuse holder. Spare fuses are provided
with your Thuraya IP Voyager terminal.
Power Cable
The Power cable uses a Phoenix contact #1718384 PC5/3 STCL-7, 62 connector and the
pinout is shown in the Table below.
Color Function
Red DC +
White Ignition Sense +
Black DC -
The optional accessory car adapter power cable, Hughes’ part number 3500472-0002,
includes a car adapter plug with a 20 Amp, 250 V fuse, and the ignition sense wire is
connected to the positive power wire in the plug.

14
•The Below Deck Unit BDU
Chapter 2Standard 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,cable ties and clamps
should be used as required to ensure that vibration and/or rubbing of the cables does not
occur.
Ignition sense (white wire)
Route and connect the white wire (ignition sense) to a switched 12 or 24Vdc 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 ignition switch is in the ACCESSORIES or RUN position.
Note: If using the optional 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. The BDU must be grounded by
connecting a 8 AWG grounding wire from the chassis ground point to the vehicle
chassis. See figure below. The ground wire should be clamped between the two nuts
ensuring both are securely tightened.
Chassis Ground
Point

•Below Deck Unit (BDU)
15
Chapter 3Below Deck Unit (BDU)Install
The BDU is generally located in an area accessible by the operator and protected from
water and heat. The ADU is generally located in a position to give clear line of sight to
the satellite and to avoid exposure of microwave radiation to personnel.
Basic BDU installation
procedure
The basic installation procedure is as follows:
1. Ensure that the BDU is located inside the vehicle in a position that is protected
from water and heat and attached to something structurally solid. Locations that
vibrate will degrade performance. Note: The BDU is not waterproof.
2. Determine the power cable routing from the BDU to the power source.
3. Determine an RF cable routing from the BDU to the ADU. The ADU will need to
be mounted so that it has a 360oclear view of the sky and is not within one meter
of personnel in the vehicle (side and top surfaces).
4. Perform the installation of the BDU per the instructions below.
Installation notes
1. Use the correct gauge of wire for both Positive and Negative wires to ensure a
minimal voltage drop under load.Suggested wire size: 14 AWG: up to 8m (26ft),
12 AWG: up to 12m (40ft), 10 AWG: up to 20m (65ft).
2. The remote switch line may be used to power the system up and down remotely.
It should be connected to a physical remote on/off switch or the vehicle’s ignition
line. When the engine is not running prolonged operation should be avoided to
prevent draining the vehicle’s battery.
3. The power must be connected to a fused 12 or 24Vdc power source. The unit is
fused, but a 15A or greater fuse is required in the source to protect against shorts
in the cabling. If connecting to a circuit in aDC panel that is already in use,
ensure that the circuit can supply the unit with up to 15A for a 12V installation or
7.5A for a 24V installation.
4. Use cable ties every 300 –450mm (12"-18").
5. BDU -Ground the chassis ground bolt to a nearby vehicle ground point via an 8
AWG wire.
6. 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.
7. With the exception of the BDU-to-antenna RF cable, do not route the power
cable outside the vehicle.

16
•The Below Deck Unit BDU
BDU mounting information
1. The BDU can be mounted in either the horizontal or vertical position.
2. Install the BDU in a protected but ventilated area. Allow at least a 1-inch space
around top and sides to provide adequate cooling.
3. Mount the terminal onto a flat surface using at least four screws or bolts (not
supplied). Use screws or bolts with a diameter between 3.5 to 4mm. Vibration-
resistant screws or lock washers should be used.
Figure 2-1. BDU -mounting dimensions in mm.
Figure 2-2 BDU Wiring Diagram
Dimension BETWEEN Mounting Holes: 271mm
Dimen
sion
BETW
EEN
Mount
ing
Holes:
182.5
mm

•The Antenna -Above Deck Unit (ADU)
17
Chapter 4Above Deck Unit (ADU)Install
The antenna unit (ADU) is composed of the antenna element, high-power and low-
noise amplifier systems,and a mechanical tracking system housed in the radome.
The ADU is aSpaceCom HN221 2-axis antenna intended for vehicular use.
Connection to the ADU is made by aTNC connector. The single coaxial cable carries
L-band RX and TX, power,and control information.
Physical dimensions
•ADU:Size:252mm x 119mm
Weight: 2kg
Figure 3-1. ADU –Land Mobile Antenna
Antenna cable lengths
and types
The BDU has an automatic cable calibration feature that determines the loss of the
cable. The RF cable that comes standard in the terminal kit is 6meters long. If a
different cable is required for the installation, the end-to-end RF loss needs to be 10dB
+0dB/-8dB at 1.6GHz and the cable must be 50 Ohm impedance.
Note: The installer is responsible for choosing the proper type of cable for the length
required in order to meet the loss requirement.
Antenna Installation
When the Thuraya IP Voyager terminal is powered up - avoid exposure to
microwave radiation. Keep a minimum safe distance of 1meter (39 inches) to the
side and above the antenna.

18
•The Above Deck Unit (ADU)
The antenna cable carries DC power. Always power the BDU down prior to
connecting or disconnecting the antenna cable from either the antenna or the
BDU.
Keep a clear line-of-sight to the satellite. Preferably, avoid all obstructions within
three meters of the antenna. Obstructions less than 150mm (six inches) in
diameter can be ignored beyond this distance.
Do not locate the antenna close to interfering signal sources or receivers. It is
recommended that no other antennas be located within three meters of the
Thuraya Mobility antenna. If there is other equipment installed near the Thuraya
IP Voyager terminal, it is recommended to operate all equipment simultaneously
and verify there is no co-interference.
It is important for the operation and life of the Antenna and safety of personnel
that the mounting / fitting instructions are followed –improper installation will void
any warranty.

•The Antenna -Above Deck Unit (ADU)
19
Antenna Mounting
Always install the antenna so that it is in a horizontal position, even if the surface on
which it is installed e.g. roof of a vehicle, is not horizontal.
The antenna has three drainage holes at the bottom. Always install the antenna so
that clearance between bottom of antenna with drainage holes and mounting surface
is no less than 5 mm and preferably 10mm, refer to Fig.2. In order to fulfill these
criteria a set of bolts and washers has to be defined for each individual installation,
refer to Fig.1.
The M5 stainless steel washers/rubber washers and spacers in the kit are always used
and positioned as shown in Fig.1.
The 3 spacers will have identical length if the antenna is installed on a non-tilting
surface, but may require individual length adjustment if the surface is tilting.
The M5 stainless steel bolts will have identical length if the three spacers are identical
and may require individual length adjustment if spacer length are different.
Note 1: Drainage of the antenna -a simple mechanism in the form of three holes in the
dome (plastic enclosure) bottom is used. The holes are made so that water e.g. solid
drops is not likely to enter the dome and simultaneously water that has entered the
dome or moisture condensed in the dome is drained out simply by gravity. Correct
function of the drainage system is ensured by following the correct installation
requirements as shown in Figures 1 and 2.
Note 2: Antenna Cable -it is important to protect against moisture using self-
amalgamating tape (or similar) wrapped around the coaxial connector at the ADU.
Also, secure the antenna cable at short intervals to prevent movement and stress.

20
•The Above Deck Unit (ADU)
Antenna Magnetic Mounting
Three magnetic mounts (part number 1502819-0003) are optional for the antenna
installation. These mounts will withstand 100 mph wind force when properly installed
on a flat metal surface such as a vehicle’s roof.
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.
Now 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
tape, or similar, wrapped around the coaxial connector. Secure the RF cable at short
intervals to prevent movement and stress.
Note 1: Removing the Antenna -use your hand to pry underneath the antenna near
one of the magnets and lift.