Hughes EchoStar Mobile 4500 User manual

Hughes 4500
Install Guide
H63998
Revision B
April 17, 2020

Copyright © 2020 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 and Hughes Network Systems are trademarks of Hughes Network Systems, LLC. All other
trademarks are the property of their respective owners.

Contents
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Contents
Contents ............................................................................................3
Understanding safety alert messages ...............................................4
Messages concerning personal injury........................................................... 4
Messages concerning property damage....................................................... 4
Safety symbols............................................................................................. 5
Additional symbols.................................................................................. 5
Warnings for satellite terminal..................................................................... 5
Equipment users.......................................................................................... 7
Chapter 1
Installation Instructions....................................................................9
Overview ..................................................................................................... 9
Quick start ................................................................................................... 9
Determining where to install the Terminal................................................. 10
Optional Installation Items......................................................................... 10
Magnetic Mounting Kit ......................................................................... 10
Fixed Mounting Bracket Kit ................................................................... 11
Terminal Installation using the Optional Mounting Kits .............................. 13
Terminal Installation using the Magnetic Mounting Kit ......................... 13
Terminal Installation using the Fixed Mounting Bracket Kit ................... 14
System Power Requirements ..................................................................... 16
Terminal Connector ................................................................................... 16
Vehicular installation ................................................................................. 18
Terminal power connection .................................................................. 18
Vehicular power schematics.................................................................. 18
Fixed installation........................................................................................ 19
Terminal power connection .................................................................. 19
Chapter 2
Technical specifications...................................................................20
Bracket ...................................................................................................... 20
Screws and Washers .................................................................................. 20

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Understanding safety alert messages
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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 DANGER,
WARNING, CAUTION, or NOTICE, 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 DANGER, 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.
CAUTION indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury.
Messages concerning property damage
A NOTICE concerns property damage only.
NOTICE is used for advisory messages concerning possible property damage,
product damage or malfunction, data loss, or other unwanted results—but
not personal injury.

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Safety symbols
The generic safety alert symbol
calls attention to a potential personal injury hazard. It appears next to the
DANGER, WARNING, and CAUTION signal words as part of the signal word label.
Other symbols may appear next to DANGER, WARNING, or CAUTION to indicate
a specific type of hazard (for example, fire or electric shock). If other hazard
symbols are used in this document they are identified in this section.
Additional symbols
This document uses the following hazard symbols:
Warning: Potential Radio Frequency (RF) hazard. Where you
see this alert symbol and WARNING heading, strictly follow
the warning instructions to avoid injury to eyes or other
personal injury.
Warning: Where you see this alert symbol and WARNING
heading, strictly follow the warning instructions to avoid
personal injury.
Danger: Electric shock hazard: Where you see this alert
symbol and DANGER heading, strictly follow the warning
instructions to avoid electric shock injury or death.
Warnings for satellite terminal
Do Not Stand near by the Antenna: This device emits radio
frequency energy. To avoid injury, do not place head or other
body parts in front of the satellite antenna when system is
operational. Maintain one meter distance from the terminal
while active.
General: Handle your Satellite Terminal with care. The unit is
weather resistant per IEC 60529 IP67; however, do not submerge
the unit. Avoid exposing your Satellite Terminal to extreme hot or
cold temperatures outside the range -25° C to +65° C.
Avoid placing the Terminal close to cigarettes, open flames or
any source of heat.
Changes or modifications to the Terminal not expressly approved
by Hughes Network Systems could void your authority to operate
this equipment.
Only use a soft damp cloth to clean the Terminal.
To avoid impaired Terminal performance, please ensure the
unit’s antenna is not damaged or covered with foreign material
like paint or labeling
When inserting the SIM, do not bend it or damage the contacts in
any way. When connecting the interface cables, do not use
excessive force.

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Understanding safety alert messages
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In the Vicinity of Blasting Work and in Explosive Environments:
Never use the Satellite Terminal where blasting work is in
progress. Observe all restrictions and follow any regulations or
rules. Areas with a potentially explosive environment are often,
but not always, clearly marked. Do not use the Terminal while at a
petrol filling station. Do not use near fuel or chemicals.
Qualified Service: Do not attempt to disassemble your Satellite
Terminal. The unit does not contain consumer-serviceable
components. Only qualified service personnel may install or
repair equipment.
Accessories: Use Hughes approved accessories only. Use of
non-approved accessories may result in loss of performance,
damage to the Satellite Terminal, fire, electric shock or injury.
Connecting Devices: Never connect incompatible devices to the
Satellite Terminal. When connecting the Satellite Terminal to any
other device, read the device’s User Manual for detailed safety
instructions.
Pacemakers: The various brands and models of cardiac
pacemakers available exhibit a wide range of immunity levels to
radio signals. Therefore, people who wear a cardiac pacemaker
and who want to use a Satellite Terminal should seek the advice
of their cardiologist. If, as a pacemaker user, you are still
concerned about interaction with the Satellite Terminal, we
suggest you follow these guidelines:
Maintain a distance of one meter from the main antenna front
and sides and your pacemaker
Refer to your pacemaker product literature for information on
your particular device
If you have any reason to suspect that interference is taking
place, turn off your Satellite Terminal immediately.
Hearing Aids: Most new models of hearing aids are immune to
radio frequency interference from Satellite Terminals that are
more than 2 meters away. Many types of older hearing aids may
be susceptible to interference, making it very difficult to use
them near a Terminal. Should interference be experienced,
maintain additional separation between you and the Satellite
Terminal.
Electrical Storms: Operation of the Satellite Terminal during
electrical storms may result in severe personal injury or death.

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Equipment users
User must be a skilled person. Designated users should not be exposed to
conditions that could cause pain or injury, nor intentionally caused said
conditions.

Chapter 1 • Installation Instructions
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Chapter 1
Installation Instructions
Overview
This Install Guide provides instructions on how to manually mount a Hughes
4500 Terminal using Hughes Optional Installation Items. Please refer to the
following documents for more details:
1. Quick Start Guide (3004339-0001):
This guide focuses on the instructions to unpack and bring up the
Hughes 4500 Terminal for the first time.
2. User Guide:
This guide provides the most up to date information available on the
Hughes 4500 Terminal including configuration details and
troubleshooting suggestions.
Quick start
Here are the instructions to bring up Hughes 4500 Terminal for the first time:
1. Remove the SIM door using a Philips screwdriver
2. Install the USIM into the Terminal unit before powering up the unit
3. Connect the terminal barrel connector to power and Ethernet and power up
the Terminal
a. Refer to Sections ‘System Power Requirement’ and ‘Terminal
Connector’of this Guide for more details related to the terminal
connector
4. After powering up the Hughes 4500 Terminal will register and establish
an IP context automatically by default. The LED states are provided in the
table below
State
LED
Powering up
Solid GREEN
Network acquisition
GREEN flashing
Registered and IP context active
Solid GREEN
Hardware fault
Solid RED
Table 1: LED states
USIM port

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Chapter 1 • Installation Instructions
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5. Connect the Hughes 4500 Terminal to your computer via Ethernet or the
USB port under the SIM door. Open a web browser and enter the
address 192.168.128.100 (Ethernet) or 169.254.1.1 (USB) to access the
home page of the UT Web User Interface. The many configuration
options are documented in the 4500 User Guide from which can be
downloaded from http://echostarmobile.com
6. Confirm Internet connectivity via the Ethernet port (the USB port is
restricted to local configuration only) using a browser to access a remote
web site
7. Reinstall the SIM Door and gasket to maintain the water and dust sealing
of the enclosure.
Note: Please note that the torque specification on the SIM door assembly
is 0.68 Nm (6 lbf in).
Determining where to install the Terminal
For your Hughes 4500 Terminal to work correctly, it must be installed in a
location that provides a clear view of the sky in all directions for a vehicular
install and a clear view to the satellite in a fixed install. The terminal does not
need to be pointed but it should be mounted on a roughly horizontal surface.
Optional Installation Items
Please refer to the Hughes catalog and pricelist for the purchase of any optional
installation items.
Magnetic Mounting Kit
This kit may be used for mounting the Hughes 4500 Terminal to a horizontal
magnetic flat surface. The mounting kit includes all the parts needed to install
the magnetic mount to the Terminal:
•One mounting plate with two circular magnets
•Four screws and four washers, to attach the mounting plate to the
Terminal.
Refer to Chapter 2 for more technical specifications about the screws and the
washers.

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Item
Part
Number
Specifications
Magnetic Mounting Kit
3501354-0001
High quality corrosion resistant plate
with two circular magnets attached, ideal
for vehicular installations
Table 2: Magnetic Mounting Kit
Figure 1: Magnetic Mounting Bracket
Fixed Mounting Bracket Kit
This kit may be used for mounting the Hughes 4500 Terminal to a vertical flat
surface. The mounting kit includes:
•One bracket
•Four screws and four washers, to attach the bracket to the Terminal.
Mounting the bracket on the pole can be accomplished by using U-clamps that
can be sourced separately.
Refer to Chapter 2 for more technical specifications about the bracket, the
screws and the washers.
Item
Part
Number
Specifications
Fixed Mounting Bracket
3501353-0001
High quality corrosion resistant angle
bracket ideal for vertical installations
Table 3: Fixed Mounting Bracket Kit

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Figure 2: Fixed Mounting Bracket
Cable Options
Several readymade cables are available for connecting to the 4500 Hughes
Terminal.
Item
Part
Number
Specifications
Power & Data Cable, blunt wire, 5m
3501314-0002
Blunt wire including the mating barrel
connector to the 4500 Terminal
Power & Data Cable, blunt wire, 10m
3501314-0003
Blunt wire including the mating barrel
connector to the 4500 Terminal
Power & Data Cable, cig lighter plug &
RJ45 socket, 5m
3501314-0004
Ideal for temporary vehicular
installations
Mating Power & Data Connector, bare
9509554-0001
For custom cable installations
Custom Power & Data Cable, 8.5mm
OD, 100m
9509573-0001
For custom cable installations
Table 4: Cable Options in Catalog
Figure 3: Cables Options

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Terminal Installation using the Optional Mounting Kits
Terminal Installation using the Magnetic Mounting Kit
Using the Magnetic Mounting Kit, the Hughes 4500 Terminal can be installed on
any horizontal metallic surface (e.g. on the top of a vehicle).
All the parts included in the Mounting Kit (one plate with two magnets, washers
and screws) should be used and positioned as shown in the following figures
and described below:
1. Place the plate so its four holes must face the equivalent ones on the
Terminal. The holes on each side have the same dimensions
2. Position all the washers touching the head of each screw
3. Tighten all the screws so that washers are compressed
Note: Please note that the torque specification for the screws is 1~1.25 Nm
(9.0~11.0 lbf in).
4. Decide where you are going to install the Terminal
5. Place the assembly so the magnets are on top of the horizontal surface
6. Ensure the Terminal is stable, and it is not moving
7. Refer to the 3004339-0001 Hughes Quick Start Guide for more details to
install the SIM and bring up the Terminal
8. Refer to the User Guide for further details.
Figure 4: Magnetic Mounting Kit Installation

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Chapter 1 • Installation Instructions
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Figure 5: Positioning the washers and screws Figure 6: Placing the plate and tightening the screws
Terminal Installation using the Fixed Mounting Bracket Kit
Using the Fixed Mounting Bracket Kit, the Hughes 4500 Terminal can be
installed on any vertical surface.
For pole mounting the user may source appropriate U-bolts to attach the
supplied mount to the pole. Examples of this can be found at
https://www.mcmaster.com/u-bolts as well as other such hardware sources.
Figure 7: Fixed Mounting Bracket Installation
All the parts included in the Fixed Mounting Bracket Kit (one bracket, the
washers and the screws) should be used and positioned as shown in following
figures and described below:
1. Point the bracket in the correct way, with one side facing the Terminal and
the other side facing the vertical surface
2. Place the bracket so its four holes must face the equivalent ones on the
Terminal. The holes on each side have the same dimensions

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3. Position all washers touching the head of each screw
Note: Please note that the torque specification for the screws is 1~1.25 Nm
(9.0~11.0 lbf in).
4. Tighten all screws so that washers are compressed
5. Ensure the Terminal is stable, and it is not moving
6. Refer to the 3004339-0001 Hughes Quick Start Guide for more details to
install the SIM and bring up the Terminal
7. Refer to the User Guide for further details.
Figure 8: Positioning the washers and screws Figure 9: Placing the plate and tightening the screws

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Chapter 1 • Installation Instructions
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System Power Requirements
The Terminal must be connected to a power supply that has the following
requirements.
System Component
Power
Requirement
Terminal Input Voltage Minimum
10 VDC
Terminal Input Voltage Maximum
28 VDC
Power Cable Length Maximum
30 m
Power Supply Voltage Suggested
(with a Power cable length < 10m)
12 VDC
Power Supply Voltage Suggested
(with a Power cable length > 10m)
19 VDC
Power Supply Requirement
16 W
Power Supply Peak Current
3.5 A
Table 5: System Power Requirements
Note: Ensure the Power source is fused at the source to protect against any
short circuits in the Terminal power wiring. A 5A slow blow fuse is
recommended.
Terminal Connector
The Terminal connector has provisions for the positive DC (red wire) and the
ground (black wire) lines along with a Remote Switch/Ignition (white wire). The
Remote Switch/Ignition can be used for vehicles to ensure Power is only
supplied to the Terminal when the Ignition switch is ON. If the Remote
Switch/Ignition wire is not used, then a jumper wire must be connected
between Pin 1 and Pin 3 or connect Pin 1 to the Power source.

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Figure 10: Terminal Connector with pinout Table 6: Connector Pinout
Figure 11: Terminal Connector
Pin
Wire Color
Function
1
White
Remote Switch/Ignition
2
Black
Ground
3
Red
Power +12VDC
1a
Green
Ethernet RX-
2a
White/Green
Ethernet RX+
3a
Orange
Ethernet TX-
4
White/Orange
Ethernet TX+
5
Yellow
unused

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Chapter 1 • Installation Instructions
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Vehicular installation
Terminal power connection
For vehicular use, determine if the Remote Switch/Ignition line will be used or
not. If used, the Terminal will be powered up or down when the vehicle’s
ignition is switched on or off. Refer to Figure 13 for the power schematic.
Note: If an Ignition Sense line is NOT used, the Modem will be powered
independently of the Ignition being switched on or off –this could lead to the
vehicle battery being completely discharged.
Pin
Wire Color
Function
Details
1
White
Remote
Switch/Ignition
Link Pin 1 & 3 if
Ignition not enabled
2
Black
Ground
3
Red
Power +12VDC
Table 7: Power plug pin-out
Vehicular power schematics
Figure 12: Vehicular wiring configuration (using Ignition Sense / Remote Switch)

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Figure 13: Vehicular wiring configuration (without ignition sense) with pins 1 & 3
connected
Fixed installation
Terminal power connection
The Hughes 4500 Terminal can be powered by a direct source –see System
Power Requirements and Terminal Connector sections for more details.

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Technical specifications
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Chapter 2
Technical specifications
Bracket
Figure 14: Detailed 2D view of the bracket
Screws and Washers
Part
Type
Quantity
Details
Screw
Pan Head, Cross Recessed,
Stainless Steel
4
- Diameter = M5.0
- Pitch = 0.80 mm
- Length = 10mm
Washer
Spring Lock, M5, Stainless
Steel
4
- Diameter = M5.0
Table 8: Technical Specifications of the screws and washers