N304JR - ICA AirCell ST 3100 - Telephone

ST 3100
Installation Manual
Satellite Telephone System
Transceiver P/N 400-10680-001 and -002
Installation Manual P/N 800-10680

Revision C, May 2007
AirCell® LLC
1172 Century Drive, Suite 280, Building B
Louisville, CO 80027
United States of America
Distribution Statement: This publication is for the Satellite Telephone products only and is to be
used by Customers and authorized AirCell® agents only. Send requests for additional copies of
this document to Corporate Publications Coordinator or e-mail at (cpc@AirCell.com).
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PROPRIETARY NOTICE
This document and the information disclosed herein are proprietary data of AirCell®. Neither this
document nor the information contained herein shall be used, reproduced, or disclosed to others without
written authorization of AirCell®, except to the extent required for installation of recipient’s equipment.
Notice
Freedom of Information Act (5 USC 552) and Disclosure of
Confidential Information Generally (18 USC 1905)
AirCell® is furnishing this document in confidence. The information disclosed here falls within exemption
(b)(4) of USC 552 and the prohibitions of 18 USC 1905. For further information, please contact:
Corporate Publications Coordinator

AirCell® LLC
Louisville, CO 80027
Telephone: (303) 379-0200
FAX: (303) 379-0279
Copyright 2007 AirCell® LLC

All Rights Reserved
Information in this document is subject to change without notice and does not represent a commitment on
the part of AirCell®.
Trademark Acknowledgements
Inmarsat® is a registered trademark of the International Maritime Satellite Organization (IMSO) and is
licensed by IMSO to Inmarsat Limited and Inmarsat Ventures plc. Inmarsat’s product names are either
trademarks or registered trademarks of Inmarsat.
uniHub™ is a registered trademark of On-Go, Inc.
Other product and company names mentioned in this manual may be trademarks or trade names of their
respective owners.
Page i
800-10680-C, May 2007

RECORD OF REVISIONS
RELEASE RELEASED
REVISION DESCRIPTION DATE BY
A Original Document October 2002 AirCell®
Revised to delete Handset and Antenna specific

B information from this manual in order to create June 2005 AirCell®
separate Handset and Antenna manuals.
Revised for the addition of the -002 non-POTS

configuration, the functionality of revised volume
C potentiometers on the -001 Transceiver, and May 2007 AirCell®
incorporated miscellaneous editorial comments and
revisions.
Page ii
800-10680-C, May 2007

TABLE OF CONTENTS
Subject Page
PROPRIETARY NOTICE............................................................................................................................... i
RECORD OF REVISIONS ............................................................................................................................ ii
TABLE OF CONTENTS .............................................................................................................................. iii
LIST OF FIGURES ....................................................................................................................................... v
LIST OF TABLES ........................................................................................................................................ vi
1.0 INTRODUCTION.............................................................................................................................1-1
1.1 General.....................................................................................................................................1-1
1.2 Unpacking................................................................................................................................1-2
1.3 Planning...................................................................................................................................1-2
1.4 List of Abbreviations and Acronyms ....................................................................................1-2
1.5 Advisories................................................................................................................................1-3
1.6 List of Related Publications...................................................................................................1-3
2.0 DESCRIPTION AND OPERATION ................................................................................................2-1
2.1. Introduction .............................................................................................................................2-1
2.2. Description and Overview......................................................................................................2-2
2.2.1. Handset (Standard Handset shown) ................................................................................2-2
2.2.2. Satellite Transceiver and Mounting Tray .........................................................................2-3
2.2.3. Satellite Patch Antenna (Standard Antenna Shown) ......................................................2-4
3.0 INSTALLATION PROCEDURES ...................................................................................................3-1
3.1. Planning...................................................................................................................................3-1
3.2. Equipment Location ...............................................................................................................3-1
3.3. Cable Routing .........................................................................................................................3-2
3.4. Antenna Selection ..................................................................................................................3-2
3.5. Handset Selection...................................................................................................................3-2
3.6. ST 3100 Transceiver Location...............................................................................................3-2
3.7. Power, Handset, and Audio Cabling.....................................................................................3-2
3.8. Ring Detect ..............................................................................................................................3-2
3.9. Intercom Alert .........................................................................................................................3-3
3.10. Cabling.....................................................................................................................................3-3
3.11. Satellite Antenna Installation Cable Guide ..........................................................................3-4
4.0 TESTING AND SETUP ...................................................................................................................4-1
4.1. Introduction .............................................................................................................................4-1
4.2. Testing .....................................................................................................................................4-1
4.3. Test Equipment.......................................................................................................................4-1
4.4. Test Results ............................................................................................................................4-1
4.5. Maintenance and Continued Airworthiness.........................................................................4-2
4.6. Telephone Operations (Standard Handset Shown) ............................................................4-3
4.7. Post-Installation Check, Programming, and Setup.............................................................4-3
4.7.1. System Check Out..............................................................................................................4-4
4.7.1.1. Audio Level Adjustments (Revision M and earlier)................................................4-4
4.7.1.2. Audio Level Adjustments (Revision N and later) ...................................................4-6
5.0 CLEANING......................................................................................................................................5-1
Page iii
800-10680-C, May 2007

TABLE OF CONTENTS
Subject Page
5.1. Introduction .............................................................................................................................5-1
5.2. Recommended Cleaning Materials .......................................................................................5-1
5.3. Procedure ................................................................................................................................5-1
6.0 FITS AND CLEARANCES..............................................................................................................6-1
6.1. Satellite Transceiver...............................................................................................................6-1
7.0 SYSTEM SPECIFICATIONS ..........................................................................................................7-1
7.1. Purpose....................................................................................................................................7-1
7.2. Product Definition...................................................................................................................7-1
7.3. Associated Reference Documents .......................................................................................7-1
7.4. Technical Specifications........................................................................................................7-1
8.0 SPECIAL TOOLS, FIXTURES, AND EQUIPMENT .......................................................................8-1
8.1. Introduction .............................................................................................................................8-1
8.2. Test Setup and Calibration ....................................................................................................8-1
9.0 PARTS LIST ...................................................................................................................................9-1
9.1. Introduction .............................................................................................................................9-1
9.2. Parts List..................................................................................................................................9-1
9.3. Associated Equipment ...........................................................................................................9-1
10.0 WIRING DIAGRAMS..............................................................................................................10-1
10.1. Wiring Diagrams ...................................................................................................................10-1
APPENDIX A: Troubleshooting Procedures......................................................................................... A-1
APPENDIX B: Instructions for Continued Airworthiness ................................................................... B-1
Page iv
800-10680-C, May 2007

LIST OF FIGURES
Figure Title Page
Figure 2.1. ST 3100 Satellite System Block Diagram ....................................................................2-1

Figure 2.2. ST 3100 Satellite System Standard Components .......................................................2-1
Figure 2.3. Handset and Cradle .......................................................................................................2-2
Figure 2.4. ST 3100 Transceiver ......................................................................................................2-3
Figure 2.5. ST 3100 Transceiver Mounting Tray ............................................................................2-3
Figure 2.6. Satellite Patch Antenna .................................................................................................2-4
Figure 4.1. Handset Keyboard .........................................................................................................4-3
Figure 4.2. ST 3100 Transceiver (Top View) (Revision M and earlier) .........................................4-5
Figure 4.3. Conference Call Audio Level, Side Tone Adjustment, and Mic Bias........................4-5
Figure 4.4. ST 3100 Transceiver (Top View) (Revision N and later).............................................4-6
Figure 4.5. Handset Volume Audio Level, Side Tone Adjustment, and Mic Bias .......................4-7
Page v
800-10680-C, May 2007

LIST OF TABLES
Table Title Page
Table 3.1. Satellite Channel RF Antenna Cable Guide .....................................................................3-5
Page vi
800-10680-C, May 2007

1.0 INTRODUCTION
1.1 General
This installation manual (800-10680) provides the required instructions to install the AirCell® Satellite
Transceiver (ST) 3100 system (AirCell® ST 3100). This system allows for two-way communications from
the aircraft, including voice or PC (via the Iridium on-board modem). These services are available when
the aircraft is in the air or on the ground. On the ground or in the air, the satellite communications link is
provided using the Iridium LEO (Low Earth Orbit—485 miles altitude) array of 66 satellites that enable
total earth coverage.
An Iridium-approved antenna is mounted on the top of the aircraft to provide the Radio Frequency (RF)
interface for the aircraft to satellite connection. The AirCell® ST 3100 system provides options for multiple
handsets. The AirCell® ST 3100 provides three (3) handset voice channels and a single Audio Panel
interface. Optimal handset performance is realized when handsets are wired directly to a dedicated voice
channel. When required, two handsets can be wired in parallel to a single voice channel. However,
audio quality during conferencing (intercom) between handsets deteriorates when wired in this manner. If
conferencing (intercom) is required, it is best to use a separate voice channel for each handset. The
Satellite Transceiver also has an on-board modem that accepts RS-232 serial data from a Personal
Computer, Cabin Entertainment Systems and Multi-Function Display systems.
Note
ST 3100 part number 400-01680-001 has a Plain Old Telephone System (POTS) interface and the 400-
10680-002 has no POTS interface. These transceivers are identical including revision levels; the only
exception is the -002 configuration lacks a POTS module installed on the motherboard.
The ST 3100 System was tested for Operational Shock and Crash Safety to DO-160D, Section 7,
Category B. Radiated RF Interference met the conditions of DO-160D, Section 21, Category M.
Equipment Specifications are found in Section 7.0. Install the AirCell® ST 3100 Transceiver in locations
that are free of water, spray, or other fluids, whether by direct contact or condensation. When installing
the AirCell® ST 3100 system in the aircraft, carefully follow this Installation Manual.
The AirCell® ST 3100 system meets environmental requirements identified in RTCA DO-160D, as defined
in Section 4, Category F2. Any alteration of this product voids the federal Aviation Administration (FAA)
or Federal Communications Commission (FCC) certification and the AirCell® warranty. This publication is
not to be used in lieu of a Supplementary Type Certificate (STC) or any other FAA approval. FAA form
337 approval is usually required for installation of this equipment.
Note
The material in this manual is subject to change. Before planning or performing any installation operation,
check with AirCell® www.AirCelldealers.com Dealer Info website to verify that this manual is complete and
is the latest revision. The Record of Revisions, Record of Temporary Revisions, Service Bulletin List, and
List of Effective Pages found at the front of this manual must match that issued as current by AirCell®.
www.AirCelldealers.com will have additional information that may be useful such as, Technical Bulletins
and Tech Tips and Installation and Troubleshooting Tips.
Introduction Page 1-1

Section 1 800-10680-C, May 2007

AirCell® LLC welcomes your comments, suggestions, and corrections concerning this manual. Please
include in your correspondence the publication number, equipment part number, page or figure number,
and a brief description of any problem or consideration you noted. Please send your comments to:
cpc@aircell.com
or
AirCell® LLC
Corporate Publication Coordinator
Louisville, Colorado 80027
1.2 Unpacking
Unpack the equipment carefully to save the integrity of the shipping package. Inspect each component
for possible shipping damage. Report any damage to AirCell® immediately. Use original packing material
to return equipment to AirCell®.
1.3 Planning
Proper and careful planning is essential for reliable system performance and ease of maintenance. The
following are some considerations to follow when planning the installation:
Æ Study this manual carefully to get the complete picture of the installation process.
Æ Visit www.AirCelldealers.com for additional information that may be useful, such as Technical Bulletins
and Tech Tips and Installation and Troubleshooting Tips.
Æ Plan the location of the required equipment to ensure that the cable restrictions are met.
Æ Verify that adequate airflow is provided for equipment cooling.
Æ Check cable routing, connector access (90 degree or straight), and determine cable lengths.
Æ Ensure easy accessibility to connectors for future repairs.
Æ Plan rack or tray layout to accommodate dual (side-by-side) equipment mounting.
1.4 List of Abbreviations and Acronyms
A ampere MTBF Mean Time Between Failures

AC Advisory Circular mV millivolt
ASE Aircraft Subscriber Equipment NEMA National Electrical Manufacturers
Association
AWG American Wire Gauge PC Personal Computer
dB decibel PL Parts List
DC Direct Current P/N Part Number
FAA Federal Aviation Administration POTS Plain Old Telephone System
FCC Federal Communications Commission RF Radio Frequency
ICD Interface Control Drawing SAE Society of Automotive Engineers
LRU Line Replaceable Unit ST Satellite Transceiver
mA milliampere STC Supplemental Type Certificate
milliohm .001 of an ohm V Volts
MHz Megahertz VDC Volts Direct Current
DO-160D Environmental conditions and test procedures for airborne equipment development are
produced by RTCA. The FAA generally accepts these conditions and procedures.
RTCA Radio Technical Commission for Aeronautics: a private, not-for-profit corporation that brings
industry and government together to address the needs of the aeronautical community.

Section 1 800-10680-C, May 2007

1.5 Advisories
WARNING
Statements in this Section contain critical safety information. Read these statements carefully
before installing this unit.
WARNING
Observe standard safety precautions and wear safety glasses to prevent personal injury while
installing this unit in the aircraft.
WARNING
Shut off power before connecting or disconnecting the Telephone System Components (AirCell®
ST 3100 system), as voltage transients may damage the unit or the interface wiring.
WARNING
Follow the manufacturer’s safety guidelines when using any solvents, epoxies, flammable liquids,
or any other materials during the installation processes. Some of these products are toxic to the
skin, eyes, and respiratory tract. Avoid prolonged contact and use only in well-ventilated areas.
WARNING
Components or subassemblies found in this unit may contain materials such as beryllium oxide,
acids, lithium, radioactive material, mercury, etc. that can be hazardous to your health. If the
component enclosure seal is broken, precautions must be taken against personal contact or
inhalation in accordance with Occupational Safety and Health Administration (OSHA)
requirements 29 Code of Federal Regulations (CFR) 1910.1000 or superseding documents. Any
alteration of this product voids the FAA or Federal Communications Commission (FCC)
certification and the AirCell® warranty.
CAUTION
Use Isopropyl Alcohol carefully as it may react with some plastics in the area. Isopropyl Alcohol
should be used to clean connector contacts and metal parts, if required.
1.6 List of Related Publications
The following list includes related publications for the AirCell® ST 3100 Telephone system:
Publication Publication Number
AirCell® Antenna Installation Manual AirCell® 800-10355
AirCell® Handset Installation Guide AirCell® 800-10055
Acceptable Methods, Techniques, and Practices - Aircraft Alterations* FAA Advisory Circular
(AC) 43.13-2A
Acceptable Methods, Techniques, and Practices - Aircraft Inspection and Repair* FAA AC 43.13-1B
Environmental Conditions and Test Procedures for Airborne Equipment DO-160D
*Installation of the AirCell® ST 3100 shall be performed in accordance with these FAA Advisory
Circulars (as applicable).

Section 1 800-10680-C, May 2007

This Page Intentionally Blank

Section 1 800-10680-C, May 2007

2.0 DESCRIPTION AND OPERATION
2.1. Introduction
Satellite
Handset Transceiver
Handset
Cradle
On-Board
RS-232
Modem
Handset
Handset Cradle
Figure 2.1. ST 3100 Satellite System Block Diagram
The AirCell® ST 3100 Satellite system provides both voice and data transfer options. The system enables
telephone communications when the aircraft is on the ground or in the air via satellite, plus the option to
have multiple handsets in the aircraft for conference-type calls.
Standard Black Handset (P/N SatelliteTransceiver Standard Iridium Patch

400-10035-00X) with Modified P/N 400-10680-001 OR Antenna
Cradle (P/N 400-10038-00X) P/N 015-10306-001
P/N 400-10680-002
(RJ11/RJ45 Jacks)
(non-POTS) (Top Mount Only)
Figure 2.2. ST 3100 Satellite System Standard Components
Note
Refer to AirCell® Handset Installation Guide P/N 800-10055 and AirCell®Antenna Installation Manual
P/N 800-10355 for other options and details.
Description and Operation Page 2-1

Section 2 800-10680-C, May 2007

2.2. Description and Overview
2.2.1. Handset (Standard Handset shown)
The ringer volume is not

®
adjustable with AirCell
corded handsets.
To adjust the volume on
the earpiece, press the UP
or DOWN arrows.
Handset Cradle
Secure locking for
storage.
To place a call, enter

the phone number
RJ-45 connector for and press SND.
®
AirCell Handset (RJ-
11 connector is not
used).
To receive a call, press
SND or lift the handset
and press SND.
The PWR button has no function

with a ST 3100 system
The System will come ON with the
Avionics Master. A start-up beep
To hang up or end a
will occur with a power up initiated
call, press END.
from the Avionics Master.
Figure 2.3. Handset and Cradle
The handset provides voice communications and control of the AirCell® ST 3100 system. The
handset supplies and receives information to and from the Transceiver. The standard 21-inch
coil cord will extend to a little over six feet. The Handset and Cradle come in three distinctive
colors of your choice: black, beige, and gray. Mount the Handset and Cradle in any position;
however, the assembly does contain a small internal magnet, so be aware of its possible affect
on aircraft instruments and compass systems. Verify compass system deviation after the AirCell®
ST 3100 system installation is complete.

Section 2 800-10680-C, May 2007

2.2.2. Satellite Transceiver and Mounting Tray
The AirCell® ST 3100 is

11.0” long, 3.56” wide, and 6.00”
high. The finish is textured blue
powder-coating over chemical film.
The Transceiver’s Mounting Tray Access Door for
Mic Bias/Audio
secures the unit with a flange at the Level Adjust
back and a locking device in the
front. Detents provide locking for
the knob, to ensure that the
Transceiver will stay in place when Satellite Antenna; Type N
Female Connector
it experiences vibration. A split,
rolled tube provides spring tension
to keep the knob locked in position.
An optional rail mounting kit is also
available (refer to Section 6.0 for Auxiliary Connector
details). per M83723/73 ; Insert
All of the electrical Arrangement 14-15S
connections to the Transceiver are
on the front of the box, which offers
convenient access for System Connector Per
maintenance. The location of the MS3114; Insert
Transceiver in the equipment rack, Arrangement 16-26P
may suggest the use of 90º
connectors. Access to the audio
adjustments on the top of the unit
should be a factor in the equipment
location.
Figure 2.4. ST 3100 Transceiver
Refer to Section 7.1., System
Specifications, for details regarding
the environmental requirements for
this unit.
Flange and side Detents
retention to secure
Split tube offers spring
the Transceiver.
tension to the locking
device.
Figure 2.5. ST 3100 Transceiver Mounting Tray

The Mounting Tray is alodine-processed aluminum (Chem Film per MIL-C-5541, class 3 or equivalent) to
reduce the possibility of corrosion and to provide a stable grounding path. Four (4) #6 fasteners (i.e. MS
35206-229) are used to secure the tray to the aircraft structure. Location considerations for the Mounting
Tray (P/N 800007-1) are: accessibility for maintenance; lengths of required cables; and wiring. Section
7.0, System Specifications, identifies the environmental requirements of the Transceiver. The optional
Mounting Rails (P/N 151-10689-001) are alodine-processed aluminum (Chem Film permit-C-5541, Class
3 or equivalent). Optional Rails are mounted to the Transceiver via six (6) #6 fasteners (i.e., MS51957-
27), four (4) to six (6) #8 fasteners are used to secure the Mounting Rails to the aircraft structure.

Section 2 800-10680-C, May 2007

Note
ST 3100 part number 400-01680-001 has a Plain Old Telephone System (POTS) interface and
the 400-10680-002 has no POTS interface. These transceivers are identical including revision
levels; the only exception is the -002 configuration lacks a POTS module installed on the
motherboard.
Note
Component Bonding
As with any communication equipment, bonding the equipment to ground is essential for optimum
performance. Ensure that the Receiver/Transmitter Mounting Tray is bonded to the shelf, and the
shelf is bonded to airframe ground. Properly bonded, there should be 2.5 milliohms or less
between the Mounting Tray and airframe ground. Care in bonding has been shown to eliminate
erratic or poor system performance.
Note
Access Door for Audio Level, Side Tone Adjustment, and Mic Bias
Installation of multiple Handsets may require audio level adjustments for each Handset. Access
the 14 turn potentiometers by removing the small cover at the top of the unit. Use caution as the
two (2) screws are not captive and can be easily lost. The adjustments are set to mid-range at
the factory. Refer to Section 4.7.1. for Audio Level, Side Tone Adjustment, and Mic Bias
adjustment details. Refer to Section 10.0 for the Wiring Diagram for details on the separate
Handset A, B, and C audio channels, and Audio Panel interface.
2.2.3. Satellite Patch Antenna (Standard Antenna Shown)
The AirCell® Satellite Patch Antenna is P/N 015-10306-

001. This antenna is a low profile Iridium/GPS antenna
that provides continuous coverage from 1565
Megahertz (MHz) to 1626.5 MHz for excellent Iridium
applications. Mechanical configuration is a spherical-
radius molded radome that provides enhanced
protection against rain, ice, and lightening strikes.
Qualified for high-speed military aircraft as well as
general aviation applications, it has a TNC Female
connector.
Figure 2.6. Satellite Patch Antenna
Requirements of the applicable FARs may stipulate that proper Designated Engineering
Representative (DER) engineering documents (8110-3) be supplied or that the installation be
performed in accordance with an acceptable Supplemental Type Certificate (STC) for mounting
these types of antennas. These are the responsibilities of the Installer.
Note
Antenna Bonding
As with any communication equipment, bonding the Antenna to airframe is essential for optimum
performance. Ensure that the antenna is bonded to the aircraft skin. Properly bonded, there
should be 2.5 milliohms or less between the mounting screws and airframe ground. Care in
bonding has been shown to eliminate erratic or poor system performance. Iridium Antenna
bonding is essential for proper performance (as with any antenna).

Section 2 800-10680-C, May 2007

3.0 INSTALLATION PROCEDURES
3.1. Planning
Careful planning for the install of the AirCell® ST 3100 system will ensure an efficient installation with
minimum down time for the aircraft and will ensure optimal system performance and easy maintenance
access in the future. Study the aircraft for optimal antenna location, plan equipment locations with service
in mind, and select the proper cabling before ordering. The Customer will be pleased to get the aircraft
back in service promptly as the result of your planning.
Refer to Aircraft manufacturing guidelines and/or to FAA AC 43.13-1B and -2A. FAA AC 43.13-1B
(Acceptable Methods, Techniques, and Practices) Chapter 11, and FAA AC 43.13-2A (Acceptable
Techniques, and Practices-Aircraft Alterations) Chapters 2 and 3 provide excellent guidelines to ensure a
good installation.
A field-approved FAA Form 337 that references a STC as a basis for a follow-on field approval,
references to acceptable approvable data and/or DER documentation (Form 8110-3) approving
installation data, is the usual required documentation path for the installation of this system.
Note
ST 3100 part number 400-01680-001 has a Plain Old Telephone System (POTS) interface and the 400-
10680-002 has no POTS interface. These transceivers are identical including revision levels; the only
exception is the -002 configuration lacks a POTS module installed on the motherboard.
Note
Requirements of the applicable FARs may stipulate that proper DER engineering documents
(Form 8110-3) be supplied or that the installation be performed in accordance with an acceptable STC.
3.2. Equipment Location
If this is a new installation of an AirCell® ST 3100 system, you will need to comply with the installation
instructions of this manual, FARs, and FCC requirements by selecting RF cabling to satisfy the approved
requirements of the system. Keep the cable attenuation as low as possible in the cable run from the ST
3100 Transceiver to the Satellite Antenna, as the performance of the system will be greatly affected by
this cable attenuation.
Mount the Transceiver where rain or harsh environments will not be present. Refer to System
Specifications, Section 7.0, for further details regarding the environment requirements, as the AirCell® ST
3100 Transceiver is not weather proof. Avoid a completely “sealed” chamber, as ambient air movement
is required to cool the AirCell® ST 3100 Transceiver. When considering the use of ram-air for cooling,
ensure that rainwater will not be ingested and sprayed onto the equipment. Cooling can extend the Mean
Time Between Failure (MTBF) of electronic equipment located in a tightly packed avionics bay, so a fan
may be a worthwhile consideration.
Installation Procedures Page 3-1

Section 3 800-10680-C, May 2007

3.3. Cable Routing
Draw a cable routing diagram for the aircraft. Refer to Wiring Diagrams, Section 10.0, to determine the
required cables, then measure and record the required cable lengths on a worksheet. Consider the use
of straight or 90 degree connectors to satisfy the bend radius requirements of the coax and allow for
access to the top of the AirCell® ST 3100 Transceiver to make required audio adjustments. Allow for
adequate bend radius, service loops, and stress relief in all cable routes. Follow the cable specifications
of Tables 3.1. Clear and concise specifications when ordering parts will ensure an efficient installation.
The Vendors provide cable loss decibel (dB) and VSWR data for the aircraft records.
3.4. Antenna Selection
Refer to AirCell® Antenna Installation Manual P/N 800-10355 for options and installation details.
3.5. Handset Selection
Refer to AirCell® Handset Installation Guide P/N 800-10055 for options and installation details.
3.6. ST 3100 Transceiver Location
Typically, the AirCell® ST 3100 Transceiver would be located in the avionics equipment bay. However,
when choosing the location of the AirCell® ST 3100 Transceiver, the requirement to keep the cable loss
below 3.0 dB from the AirCell® ST 3100 Transceiver to the Satellite Antenna and loss less than 3.0 dB
from satellite antenna to Transceiver are major considerations. This requirement is to ensure the best
overall system performance. Refer to Table 3.1 to properly select the coax cables required to meet these
requirements.
Note
Some of the RG-style cables used in General Aviation applications are NOT ACCEPTABLE when
installing the AirCell® ST 3100 system.
3.7. Power, Handset, and Audio Cabling
When considering the location of the AirCell® ST 3100 Transceiver, longer Handset cabling rather than
longer antenna cable runs will enhance the performance of the system. Use shielded twisted pairs of
wire, as shown in Wiring Diagrams, Section 10.0, to reduce interference. Size the power leads to
maintain the proper supply voltage within the limits identified in System Specifications, Section 7.0, and
satisfy the requirements of FAA AC 43.13-1B. The telephone system will detect low battery voltage and
shut the system off.
3.8. Ring Detect
The Ring Detect (refer to Wiring Diagrams, Section 10.0) offers an annunciator function to be made
available in the aircraft. The operating conditions are as follows:
1) Pin G will go low (ground) when the telephone rings for an incoming call. Use this logic for a
visual annunciator or a Sonalert. Pin G will be low (ground) for one (1) second and off (open) for
three (3) seconds. This cycle will continue until the telephone is answered or the call attempt is
terminated.
2) Pin G will go low (ground) when there is an “Intercom Alert” signal received by the Transceiver.
Pin G will remain low (ground) for the duration of the intercom alert switch being energized.

Section 3 800-10680-C, May 2007

Note
The addition of some type of external annunciation is advisable, if only the AirCell® Cordless Handsets
are to be installed. This is due to the AirCell® Cordless Handsets having a lower ringer volume than the
corded types. The AirCell® Cordless Handset ringer can be turned down to a level that might not be
noticed in a noisy aircraft environment.
3.9. Intercom Alert
The Intercom Alert seeks a low (ground) from a momentary push button switch located near the
telephone handsets (refer to Wiring Diagrams, Section 10.0). Activation of this momentary switch will
alert the other Handset stations that intercom activity is requested. Use this logic to activate an
annunciator or Sonalert on the Ring Detect output.
3.10. Cabling
Note
Wire and Coax Installation
Installation of wire and antenna coax cables should be installed according to approved aircraft
manufacturing guidelines and/or FAA procedures documented in AC 43.13-1B. Consider cable slack,
protection from heat, and protection from chafing when installing system wiring.
Good installation practices will ensure maximum performance from the ST 3100 System. FAA AC 43.13-
2A (Acceptable Techniques, and Practices - Aircraft Alterations), Chapter 2.27, and FAA AC 43.13-1B
(Acceptable Methods, Techniques, and Practices), Chapter 11 provide excellent guidelines to ensure a
good installation. When building the system wire harness and RF cables, observe the following:
1. Plan the AirCell® cable routing so that it does not interfere with flight control cables or follow
heavy current-carrying cables, hydraulic lines, or fuel lines.
2. It is essential to use Military Specification Connectors or connectors approved for use on aircraft.
3. Refer to FAA AC 43.13-1B for the proper wire types. Wiring should conform to MIL-W-22759 or
MIL-C-27500 (AC 43.13-1B, 11, 89 or AC 43.13-1B, Tables 11-11 and 11-12) as applicable.
Installation of wire and antenna cables should be according to approved FAA procedures and
follow FAA AC 43.13-1B. Consider cable slack, protection from heat, and protection from chafing
when installing system wiring.
4. This document and attached Interface Control Drawings (ICDs) only shows a suggested circuit
breaker size, wire size & type for a typical installation:
• It is the responsibility of the Installation Agency to ensure proper wire type and size and
the use of a properly rated circuit protection device (circuit breaker). In addition, ensure
that the 28 Volts Direct Current (VDC) bus the equipment is to be connected to can
handle the additional electrical load.
• Install circuit protection (circuit breaker) of the proper amperage to handle the power
requirements and protect the wiring.
• Refer to Aircraft manufacturing guidelines and/or refer to FAA Advisory Circular 43.13-
1B, Section 11 (Aircraft Electrical Systems) for the proper wire types and circuit
protection recommendations. All wiring and coax cabling shall conform to the
flammability requirements of FAR 25.869.
• Single wire conductors shall conform to Aircraft manufacturing guidelines and/or
Fluoropolymer-Insulated Society of Automotive Engineers (SAE)-AS22759, also known
as Military (MIL)-W-22759.
• Shielded wire conductors shall conform to Aircraft manufacturing guidelines and/or
Fluoropolymer-Insulated National Electrical Manufacturers Association (NEMA) WC
27500, also known as MIL-DTL-27500.
• These wires shall be used for Power, Ground, Low Speed Signal, and Shield Drains.

Section 3 800-10680-C, May 2007

5. To reduce EMI / RFI to an acceptable level, all signal and power lines require shielded cables.
Ground the to/from audio line shields at the Transceiver end only, (i.e., TX and RX signals).
Refer to the wiring diagrams in Section 10.0.
6. FAA-approved antenna coaxial cables are required for this installation. Part 25 aircraft must meet
FAR 25.1359 requirements, which does not allow for the use of PVC-type insulation. Refer to
Section 3.11 for coax recommendations.
7. Provide proper grounding of the equipment by isolating chassis, power return wires, and signal
grounds.
Note
Component Bonding
As with any communication equipment, bonding the equipment to airframe ground is essential for
optimum performance and lightning protection. Ensure that the equipment mounting provisions
are bonded to the shelf, and the shelf is bonded to airframe ground. Properly bonded, there
should be 2.5 milliohms or less between the Mounting Tray and airframe ground. Care in
bonding has been shown to eliminate erratic or poor system performance.
Additional Shield Drain information
As an option, up to four (4) 22 American Wire Gauge (AWG) 7” drains may be combined on a
single grounding strap and then routed to airframe chassis. The ground strap should be as short
as possible, but may be realized with a maximum of 24” of insulated (18 AWG or larger).
8. Size power wires to handle 5.0 amps @ 28 volts dc.
The Wiring Diagrams in Section 10.0 provide manufacturing instructions for the wire harnesses. Notes on
the wiring diagrams provide essential instructions that will save you needless rework during installation.
Note
When up to three (3) Handsets are wired in, individual Handset volume control via the Transceiver access
panel is possible. Additional handsets may be wired in parallel per handset circuit, but volume loading
will occur and volume adjustment at the ST 3100 Transceiver may be required. The wiring diagram in
Section 10.0 provides wiring definitions for the Audio Panel, Handsets, and RS-232 connections. Multiple
RS-232/Modem connectors are allowed, but only one (1) data appliance can be connected at a time, to
prevent appliance malfunction. The system also provides an Audio Panel interface for direct integration
into the aircraft communications system.
Good wiring practices can be obtained from FAA AC 43.13-1B and should be followed. Here are a few
reminders. Know the harness routing and equipment location before you begin fabricating the harness.
Measure and record the harness and coax lengths required and add a few feet for good measure. It is
easy to cut to fit, but hard to stretch the wires. Identify and mark the wires in accordance with AC
43.13-1B. Refer to Section 10.0., ICD 655-10680, for mating connector layouts. AirCell® strongly
recommends that you purchase coax assemblies from PIC, ECS, or EMTEQ, so that a test record
accompanies the installation data. This practice also minimizes those hard-to-track-down cabling
problems. Refer to Table 3.1. for coax recommendations.
3.11. Satellite Antenna Installation Cable Guide
Important
®
Refer at AirCell Antenna Installation Manual P/N 800-10355 for details on special Inmarsat® filtering,
Iridium to Inmarsat®, and other Antenna separation details.
When the installation requires cable lengths from the Transceiver to the Satellite Antenna greater than 60
feet, please contact AirCell® Customer Service @ 1-888-286-9876 or your preferred cable Vendor.
The RF coaxial cable performance from the Transceiver to the Satellite Antenna is critical. Keep this
cable length as short as practical to enhance the satellite telephone performance. The total RF loss

Section 3 800-10680-C, May 2007

should not exceed 3.0 dB @ 1600 MHz and the VSWR should be less than 1.4:1, when the cable is
terminated in a 50-ohm load. Refer to Section 10.0, ICD 655-01680 (Wiring Diagrams).
Low-loss 50-ohm cable should be used for this interface. Three (3) recommended Vendors are:
Vendors Phone
PIC 1-800-742-3191
ECS 1-800-327-9473
EMTEQ 1-888-679-6170
Refer to Table 3.1., Satellite Channel RF Antenna Cable Guide, on the following page for cable lengths,
and suggested Vendors and part numbers for connectors, cables and adapters.
Satellite Channel RF Antenna Cable
Transceiver Cable Satellite

Antenna
Suggested Part Numbers

50-Ω “N”
Right
50-Ω Type Double Straight Straight Female
Cable Suggested Angle TNC
“N” Male Shielded TNC Male “N” Male to TNC
Length Vendors Male
Connector Coax Connector Connector Male
Connector
Cable Adapter
311501
ECS CNS922 CTS922 CTR922
PFLX240-
0-20 feet EMTEQ NMS240-1 TMS240-1 TMR240-1
500
PIC 190310 190308 190309
S33141
311201
20-40 PFLX400-
EMTEQ NMS400-1 TMS400-1 TMR400-1
feet 500
PIC 190410 190408 190409
S22089
310801
40-60 PFLX500-
EMTEQ NMS500-1 TMS500-1 TMR500-1
feet 500
PIC 190410 190408 190409
S22089
60-75
ECS CNS002 310701 CTS002 CTR002
feet
75-110 PFLX900- See
EMTEQ NMS900-1 NMS900-1
feet 500 Below*
*Requires an Amphenol P/N 79825 or Maury Microwave P/N 8817B
Table 3.1. Satellite Channel RF Antenna Cable Guide

Section 3 800-10680-C, May 2007


Section 3 800-10680-C, May 2007

4.0 TESTING AND SETUP
4.1. Introduction
Now that the installation is complete and you have complied with the wiring and cabling
requirements of this manual (800-10680-C), perform a final check of the Direct Current (DC)
power input connections to the AirCell® ST 3100 system. Verify that ground and 28 VDC
connections to the unit are correct and on the proper pin numbers. This will ensure confidence
when you apply power to the unit for the first time. After verifying that the DC power inputs are on
the proper power pins, pull open the circuit breaker and connect the power cable to the AirCell®
ST 3100 Transceiver. Close the circuit breaker.
CAUTION
Before disconnecting or reconnecting AirCell® ST 3100 system components, pull open the power
circuit breaker to avoid damage to the AirCell® ST 3100 system components or the aircraft wiring.
4.2. Testing
It is advisable to test the system to verify its proper operation. To test the system, place a call on
the Satellite network.
Operational testing of the AirCell® ST 3100 System should be accomplished in accordance with
test procedures outlined in this Installation Manual, Sections 4.6. and 4.7. Complete the required
paperwork to activate the system. For Iridium telephone activation, be sure that the
Subscriber Service Agreement (SSA) have been properly filled out and faxed to AirCell®
Customer Service @ 1-888-398-1800.
When the system has passed the operational test, verify that all Handsets are operational and
can be used at the same time, as in a conference call. Include for the aircraft records all cable
certifications, wire marking data, special diagrams used for the installation. Be sure to include the
SSA in the documentation paperwork for the aircraft. This insures that the owner has a record of
the installed serial numbers and corresponding phone number and electronic serial numbers.
4.3. Test Equipment
No special test equipment is required to determine the operational status of the ST 3100 system.
4.4. Test Results
Documentation of the test results is important for the aircraft Owner. All paperwork, special
drawings, cable routings, and special installation procedures should be included for the aircraft
records.
Testing and Setup Page 4-1

Section 4 800-10680-C, May 2007

4.5. Maintenance and Continued Airworthiness
Design and manufacturing of the AirCell® ST 3100 System allows for “On-Condition
Maintenance.” On-condition maintenance means that no periodic service requirements are
required to maintain continued airworthiness of the system. No maintenance is required until the
equipment does not perform the intended function. Cable harness repair, RF cable maintenance,
and antenna replacement can be accomplished in the field. Refer to Appendix A for additional
detailed information on maintenance, continued airworthiness and troubleshooting procedures.
Consult AirCell® LLC Technical Support to help evaluate any problem that is not resolved by
following the troubleshooting procedures in Appendix A. A Return Material Authorization (RMA)
is required for all repairs or exchanges on items returned to AirCell®. Return the Transceiver to
the factory for repair and return or call Customer Service and request that a serviceable unit be
sent to you before removing the installed unit. After factory repair or receiving the serviceable
Transceiver, consult the Installation Manual (800-10680) for post-installation checkout and
procedures to verify proper system operation in the aircraft and correct phone numbers. Be sure
to activate the replacement serviceable unit (call Customer Service @ 1-888-286-9876) before
testing it for operation as the previous Electronic Serial Number (ESN)/Phone Number
combination will no longer be valid.

Section 4 800-10680-C, May 2007

4.6. Telephone Operations (Standard Handset Shown)
The operation of the AirCell®ST 3100 Handset is very similar

to that of a typical cell phone. The AirCell® phone will power
up as the Avionics Master switch is placed in the ON position
and remain ON until the Avionics Master is again switched
OFF.
To place a call: Verify that the system is in service and note
on the Handset that the system has registered on the Satellite
network (Extension # and the Dialing instructions indication
should be in view.). Enter the telephone number on the
keypad, and press SND. Note: To place a call, nine (9) must
be entered first, then the country code (USA/Canada=1), then
the balance of the phone number.
Example: 9 + 1 303 379 0278 SND, this will call AirCell®
Customer Service.
To receive a call, lift the Handset out of the cradle and press
SND. If you are holding the Handset and it rings, press SND
to receive the call.
To adjust the volume in the earpiece, press the UP/DOWN
arrows in the upper right corner of the Handset.
To end a call, press END and return the Handset to the
cradle.
4.7. Post-Installation Check, Programming, and Setup
The following is an operational check of the ST 3100 Satellite

Telephone System. If the system passes all of these steps,
your installation is a success.
Note
Activate the Satellite Telephone System with AirCell®
Customer Service @ 1-888-286-9876 before attempting to
complete the post-installation check.
Figure 4.1. Handset Keyboard
WARNING
To remove or install equipment in the aircraft, always disconnect the power (Avionics Master switch).
Personal injury, damage to the equipment, or damage to the aircraft may result if power is left ON.

Section 4 800-10680-C, May 2007

4.7.1. System Check Out
The AirCell® ST 3100 system can be checked out while the aircraft is on the ground or if the aircraft is
outside (clear view of sky).
Lift the Handset from the cradle and observe the following:
• Verify an illuminated display and that the display indicates “IRIDIUM”, and the “NOSVC” indication
is out (this usually takes about 30 seconds if the antenna has a clear view of sky).
• Place a call by entering 9 + country code + phone number on the keyboard and then press SND.
Example: 9 + 1 303 379 0278 SND, this will call AirCell® Customer Service.
• Verify that the system is providing a clear communications link, and then press END to terminate
the call.
• If multiple Handsets are installed, repeat the above procedure for all locations.
• Conferencing Handset-to-Handset and or Handset-to-Audio Panel can also be checked at this
time. Audio Panel-to-Handset operations will be per the particulars on how the AirCell® ST 3100
system audio is interfaced to the Audio Panel.
Note
Please refer to these documents for more details. AirCell® ST3100 User Manual, Quick Calling Guide,
Cordless Handset Supplement, Handset Installation Guide.
Copies are available at http://www.AirCell®.com/service/serv_manuals.php.
4.7.1.1. Audio Level Adjustments (Revision M and earlier)

Conference Call Audio Level, Side Tone Adjustment, and Mic Bias
1. The ST 3100 audio level adjustments are set by the factory to mid-range and in most
installations will not need to be altered in the field. An audio matrix is provided in the
Transceiver to allow the transmit audio levels from the Audio Panel and handsets to be
received in other handsets or Audio Panel earpiece, at a level similar to the audio level
received from an incoming call. Therefore audio levels can be balanced among the various
handsets and Audio Panel during intercom or conference calls, so that all parties talking are
heard at similar audio levels by all parties. The Handsets are identified by the letters A (HSA),
B (HSB), and C (HSC) in the wiring diagram. On the top of the Transceiver, there is an access
panel to the audio level adjustment potentiometers which are also identified A, B, and C.
Caution: the cover screws are not captive and can be easily lost. Adjust the sum of the audio
from the other Handsets to match the level of an incoming call or to the level desired. To
increase the volume level, turn clockwise. To decrease the volume, turn counterclockwise.
2. Use the additional potentiometers in the top of the Transceiver to adjust the Side Tone
transmit audio level from the Audio Panel (A/P SIDE) and the Conference Call (A/P CONF)
receive audio level to the Audio Panel. These are 14-turn potentiometers and set to mid-range
by the factory.
Note
These adjustments are minor volume adjustments that don’t adjust from a minimum to a
maximum volume level.

Section 4 800-10680-C, May 2007

SEE ACCESS DOOR VIEW
S/N:
ACCESS DOOR
Figure 4.2. ST 3100 Transceiver (Top View) (Revision M and earlier)

Caution
The access door screws are not captive and may be easily lost.
ST3100 REV ‘M’ AND EARLIER
JU M P E R S H O W N IN
"B IA S O N " P O S ITIO N
= == == = == == = ==
A N Y O TH E R P O S IT IO N
IS "B IA S O FF "
HSC CONF
HSB CONF
HSA CONF
A/P CONF
A/P SIDE
BIAS ON
H S A C O N F - H A N D S E T A C O N F E R E N C E LE V E L
H S B C O N F - H A N D S E T B C O N F E R E N C E LE V E L
H S C C O N F - H A N D S E T C C O N F E R E N C E LE V E L
A /P S ID E - A U D IO P A N E L S ID E TO N E LE V E L
A /P C O N F - A U D IO P A N E L C O N F E R E N C E LE V E L
Figure 4.3. Conference Call Audio Level, Side Tone Adjustment, and Mic Bias
Note
The audio from each of the other Handsets is summed in a matrix and sent to the Handset you are using.
To keep the audio levels consistent, the AirCell® ST 3100 Transceiver allows the summed audio to be
matched to the level of an incoming call. Match the summed audio at each Handset, using the 14-turn
potentiometer. The factory sets the 14-turn potentiometers to a mid-range setting and in most installations
will not need adjustment in the field. These adjustments are minor volume adjustments that don’t adjust
from a minimum to a maximum volume level. The Audio Panel side tone level and overall conference call
audio level are also adjustable. These adjustments change the audio level out of the Audio Panel (A/P).
The AirCell® ST 3100 Transceiver also provides a microphone bias level through the Audio Panel. This is
an ON/OFF Bias logic function enabled by a jumper.

Section 4 800-10680-C, May 2007

4.7.1.2. Audio Level Adjustments (Revision N and later)
Handset Volume Trim Level, Audio Panel Side Tone Adjustment, and Mic Bias
1. The ST 3100 audio level adjustments are set by the factory to mid-range and in most installations
will not need to be altered in the field. The AirCell® ST 3100 Transceiver incoming audio
adjustment allows Handset A, B and C to be independently adjusted using the 14-turn
potentiometer. The factory sets the 14-turn potentiometers to a mid-range setting. These
adjustments are minor volume adjustments that don’t adjust from a minimum to a maximum
volume level. The Audio Panel side tone level and volume trim level are also adjustable. These
adjustments change the audio level out of the Audio Panel (A/P). The AirCell® ST 3100
Transceiver also provides a microphone bias level through the Audio Panel. This is an ON/OFF
Bias logic function enabled by a jumper.
2. The Handsets are identified by the letters A (HSA), B (HSB), and C (HSC) in the wiring
diagram. On the top of the Transceiver, there is an access panel to the audio level adjustment
potentiometers which are also identified A, B, and C. Caution: the cover screws are not
captive and can be easily lost. Adjust the sum of the audio from the other Handsets to match
the level of an incoming call or to the level desired. To increase the volume level, turn
clockwise. To decrease the volume, turn counterclockwise.
3. Use the additional potentiometers in the top of the Transceiver to adjust the Side Tone
transmit audio level from the Audio Panel (A/P SIDE) and the Volume Trim (VOL TRIM)
receive audio level to the Audio Panel. These are 14-turn potentiometers and set to mid-range
by the factory.
Note
These adjustments are minor volume adjustments that don’t adjust from a minimum to a
maximum volume level.
SEE ACCESS DOOR VIEW

S/N:
ACCESS DOOR
Figure 4.4. ST 3100 Transceiver (Top View) (Revision N and later)

Caution
The access door screws are not captive and may be easily lost.

Section 4 800-10680-C, May 2007

Figure 4.5. Handset Volume Audio Level, Side Tone Adjustment, and Mic Bias
Note
®
The AirCell ST 3100 Transceiver incoming audio adjustment allows Handset A, B and C to be
independently adjusted using the 14-turn potentiometer. The factory sets the 14-turn potentiometers to a
mid-range setting and in most installations will not need adjustment in the field. These adjustments are
minor volume adjustments that don’t adjust from a minimum to a maximum volume level. The Audio
Panel side tone level and volume trim level are also adjustable. These adjustments change the audio
level out of the Audio Panel (A/P). The AirCell® ST 3100 Transceiver also provides a microphone bias
level through the Audio Panel. This is an ON/OFF Bias logic function enabled by a jumper.

Section 4 800-10680-C, May 2007


Section 4 800-10680-C, May 2007

5.0 CLEANING
5.1. Introduction
The appearance of a completed installation is an important aspect of Customer satisfaction. Finger

prints, smudges, wire clippings, and metal shavings should all be removed before the Customer inspects
your work. Vacuum the affected area and clean the surrounding area completely.
5.2. Recommended Cleaning Materials
Mild soap and water for most plastics is recommended.

CAUTION
Use Isopropyl Alcohol carefully as it may react with some plastics in the area. Isopropyl Alcohol should
be used to clean connector contacts and metal parts, if required.
5.3. Procedure
When Isopropyl Alcohol is used for the cleaning coax connectors, be sure to use a foam type Q-Tip to
prevent the residue that can be left by a cotton Q-Tip.
Cleaning Page 5-1

Section 5 800-10680-C, May 2007

Cleaning Page 5-2

Section 5 800-10680-C, May 2007

6.0 FITS AND CLEARANCES
6.1. Satellite Transceiver
The attached sheets (AirCell® drawing 604-10680) provide additional installation instructions for the
AirCell® ST 3100 system. In addition to general notes, the attached sheets include the AirCell® ST 3100
Transceiver and mounting provision dimensions, a connector pin-out orientation diagram, and access
door details (potentiometer adjustments).
The Notes and Tables on these pages are very important, study them carefully.
ICD 604-10680 rev E, 4 pages 11x17 will follow this page.
Note
For additional details of system components, refer to the following manuals:
• AirCell® Antenna Installation Manual P/N 800-10355
• AirCell® Handset Installation Guide P/N 800-10055.
Fits and Clearances Page 6-1

Section 6 800-10680-C, May 2007

Fits and Clearances Page 6-2

Section 6 800-10680-C, May 2007

7.0 SYSTEM SPECIFICATIONS
7.1. Purpose
This Section provides the specifications for the AirCell® ST 3100 Satellite Transceiver and various other
system components (including mounting options).
7.2. Product Definition
The AirCell® ST 3100 system utilizes the 400-10680-001 or 400-10680-002 (without POTS) ST 3100
Satellite Transceiver and is intended for aircraft applications requiring subscriber interface to the Iridium
Satellite network. The integral modem provides data communication through an RS-232 port for
computers and avionics equipment. Data/Modem speed is typically 2.4 Kbps when operating on the
Iridium network. An Audio Panel interface allows the unit to be used with cockpit audio systems and
provides selectable on/off microphone bias. High-quality intercom conferencing, which includes the Audio
Panel interface, has been incorporated. Ring Detect and Intercom Alert provide notification of incoming
call and conference request to pilots and passengers. Various antenna and handset options are
available.
The AirCell® ST 3100 Satellite Transceiver System is comprised of the following items:
400-10680-001........................................ST 3100 Satellite Transceiver w/Modem

OR
400-10680-002........................................ST 3100 Satellite Transceiver w/Modem (without POTS)
MS3126F16-26S .....................................Connector, Circular, 26 position (socket contacts

included - crimp)
800007-1 .................................................Mounting Tray, 3/8 ATR
Optional in place of Mounting Tray

151-10689-001........................................(2 each), Aircraft Subscriber Equipment (ASE) Mounting
Rail
MS51957-27............................................(6 each), Screw, Panhead, Phillips, SST, 6-32 x 0.312L
7.3. Associated Reference Documents
RTCA/DO-160D Environmental Conditions & Test Procedures for Airborne Equipment
7.4. Technical Specifications
Dimensions
Transceiver Unit ......................................11.0” L x 3.56” W x 6.00” H
(27.94cm x 9.04cm x 15.24cm)
Transceiver Unit in 3/8 ATR Tray............11.5” L x 3.75” W x 6.50” H
(29.21cm x 9.52cm x 16.51cm)
System Connector, 26-Pin ......................1.90“ L x 1.30“ diameter
System Specifications Page 7-1

Section 7 800-10680-C, May 2007

Weights
Transceiver Unit ......................................4.5 lbs. (2.04 kg)
Mounting Tray .........................................0.4 lbs. (.19 kg)
Optional Mounting Rails ..........................0.5 lbs. (.23 kg)
System Connector...................................0.1 lbs. (.045 kg)
Power Requirements ............................28 VDC, 4.0 A max. (only the XCVR requires power)
Application Note
This note documents the typical current draw requirements for typical AirCell® ST 3100 system
installed.
A typical install would be a single AirCell® ST 3100 Transceiver, standard antenna, and a single
standard Handset.
Actual values should be measured and recorded for each system installation.
Description: 28 VDC
Standby <0.30A
Transmit Ave <0.50A
Transmit Peak, approx 10% duty cycle <2.3A
Transceiver Heaters <2.8A
• Transmit Peak: The AirCell® ST 3100 Transceiver is a pulsed mode system. The duty cycle of
the transmitter is 8.3 msec per 90 msec, or just under 10%.
• Transceiver Heaters: When the temperature on the inside of the Transceiver is < -20C / -4F, the
heaters will turn on. For example, on a 28 VDC system, the heaters will draw an additional 2.8 A.
At full power transmit, the Average Current is 0.5A plus 2.8A, or 3.3A. Please note that in
general, the transceivers are warm enough, even if located outside of the temperature-controlled
cabin. The heaters generally won’t be on.
• Additional Handsets will add about 100 milliampere (mA) each to the current load of the system.
System Connectors
Transceiver Unit ......................................Type N (Female), Satellite Antenna
MS3114 (Shell size 16/26 Pin), System
M83723/73 (Shell size 14/15 Skt), Auxiliary
Antenna...................................................TNC (Female), Satellite port
Mating Connectors ..................................TNC Male [Satellite Antenna]
Type N Male [XCVR - Satellite Antenna port]
MS3126F16-26S (XCVR - System port)
M83723/76R1415N (109) (XCVR – Auxiliary port)
Operating Frequency Range................1616-1627 MHz
Transmit Power .....................................7 W max

Section 7 800-10680-C, May 2007

Ring Detector.........................................One second ON -Three seconds OFF for incoming calls
Continuous for duration of Intercom Alert
Current capability..............................2 Amperes DC (SINK only)
Voltage, withstand ............................60 VDC
Intercom Alert........................................Requires closure to ground to activate Ring Detector for

duration of switch closure
Audio Panel Interface
Transmit Mic Bias Voltage ......................+6VDC (ON/OFF selectable with jumper)
Transmit Mic Input Level .........................100 millivolt (mV) RMS, typical
Transmit Mic Input Impedance................300 ohms
Receive Output Level..............................150 mV RMS, typical
Receive Output Impedance ....................75 ohms
RS-232/Modem Port
Hardware Flow Control ...........................RTS and CTS
DTE Speed..............................................115 kbps max, 38.4 kbps recommended for revision J
and previous and 19.2 kbps recommended for revision K
and subsequent
Data Rate (IRIDIUM)...............................2.4 Kbps (typical)
Protocol, Error Correction .......................MNP4
POTS Interface (Plain Old Telephone System) (not applicable to the -002 configuration)
Current, Loop, Off Hook ..........................26 mA, nominal
Voltage, On Hook....................................52 VDC
Off Hook ..................................................9 VDC, typical
Ringing Voltage.......................................150 Volt (V) p-p with 20 mA load
Ringer Equivalence Number ...................3
Loading Impedance, Off Hook ................600 Ohms (AC), recommended
Environmental, RTCA/DO-160D
Temperature and Altitude........................Section 4, Category F2 (55K ft ASL, -55°C to +70°C)
(-67°F to +158°F)
Humidity ..................................................Section 6, Category A
Shock and Crash Safety .........................Section 7, Category B
Vibration ..................................................Section 8, Category S (Curves C, L, M, and Y)
Power Input .............................................Section 16, Category B (18 - 32 VDC)
Voltage Spike ..........................................Section 17, Category B
Emission of Radio Frequency Energy.....Section 21, Category M

Section 7 800-10680-C, May 2007


Section 7 800-10680-C, May 2007

8.0 SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
8.1. Introduction
No special tools are required for the installation of the AirCell® ST 3100 system.
8.2. Test Setup and Calibration
Refer to Section 4.0, Testing and Setup, for the procedure to verify that the unit is serviceable.
Special Tools, Fixtures, and Equipment Page 8-1

Section 8 800-10680-C, May 2007

Special Tools, Fixtures, and Equipment Page 8-2

Section 8 800-10680-C, May 2007

9.0 PARTS LIST
9.1. Introduction
The Parts List is pulled from System Specifications in Section 7.0. This Parts List specifies the
components for a single channel system installation.
9.2. Parts List
The AirCell® ST 3100 kit is comprised of the following items:
400-10680-001........................................Satellite Transceiver w/Modem

OR
400-10680-002........................................Satellite Transceiver w/Modem (without POTS)
MS3126F16-26S .....................................Connector, Circular, 26 position (socket contacts
included - crimp)
800007-1 .................................................Mounting Tray, 3/8 ATR
Optional in place of Mounting Tray

151-10689-001........................................(2 each), ASE Mounting Rail
MS51957-27............................................(6 each), Screw, Panhead, Phillips, SST, 6-32 x 0.312L
9.3. Associated Equipment
Refer to AirCell®Antenna Installation Manual P/N 800-10355 for options and details.
Refer to AirCell® Handset Installation Guide P/N 800-10055 for options and details.
Illustrated Parts List Page 9-1

Section 9 800-10680-C, May 2007

Illustrated Parts List Page 9-2

Section 9 800-10680-C, May 2007

10.0 WIRING DIAGRAMS
10.1. Wiring Diagrams
The attached sheets (AirCell® Drawing 655-10680) provide additional installation instructions for the
AirCell® ST 3100 system. In addition to general notes, the attached sheets include wiring diagrams for
the single channel system.
The Notes and Tables on these pages are very important, study them carefully.
ICD 655-10680 rev E, 9 pages 11x17 will follow this page.
Wiring Diagrams Page 10-1

Section 10 800-10680-C, May 2007

Wiring Diagrams Page 10-2

Section 10 800-10680-C, May 2007

AirCell® ST 3100 Troubleshooting Procedures
Symptom Possible Cause Discussion Verification Step(s) Ken to cross over Axxess
Symptom 1 Power is not available to The handset display should Verify that the aircraft power system (master avionics switch) is on.
ASE System always be illuminated when Verify that the ASE system circuit breaker is closed.
Handset Display is
not illuminated power is applied to the ASE Visually inspect the displays of all installed handsets in the system. If all
Transceiver. Because the failure handsets are off, proceed to the next bullet in this list. If most handsets are
of a handset display is unlikely, a illuminated, but one is not, then proceed to Symptom 2.
(One or more If all handset displays are dead, the problem is likely in the power system
‘dead’ display suggests that
handsets wiring before the ASE Transceiver. Visually check the system connections
there is a problem with the input
integrated in and the wiring harness leads between the Transceiver and the aircraft power
power to the ASE system. In the
system, no handset system. Repair or reconnect any obvious problems.
event that the one or more
displays are If needed, ring out the power lines per the system wiring diagram. Repair
handset display(s) are not
illuminated) any broken wires or rework to match the system wiring diagram.
illuminated, the user/operator
should verify that aircraft power If this procedure does not resolve the problem, contact AirCell Technical
is on and available to the ASE Support for additional guidance.
Transceiver.
Symptom 2 Bad connection or faulty In a system with multiple Some ASE systems integrate multiple handsets. If more than one handset
Handset Display is wiring between handset and handsets, if some handsets are is installed on the system, check the display on all handsets. If only one of
not illuminated Transceiver. operating and some are not, then multiple handsets is not illuminated, then the problem is either a bad handset
it is likely that either the handset or in the handset connection / wiring harness between that handset cradle
is bad or the wiring between the and the Transceiver.
(ASE System has or Perform a visual inspection to verify that all connections are made in
handset and the Transceiver is
multiple handsets, accordance with the system wiring diagram. Correct any obvious problems.
faulty.
and the displays of If all system connections are correct, then switch the ‘dead’ handset with a
Bad handset
most handsets are known good handset and retest the system. If the handset is still dead in the
on, but one new location, then the handset is bad. Contact AirCell Technical Support for
handset is not repair/replacement instructions.
illuminated.) If the known good handset is now dead, then the problem is in the system
wiring/connections between the handset and the Transceiver. Ring out the
lines per the system wiring diagram. Specifically check for 9V power and
ground leads on the HS power line from the Transceiver system connector.
Repair any broken wires or rework the system wiring harness to match the
wiring diagram.
If this procedure does not resolve the problem, contact AirCell Technical
Support for additional guidance.
AirCell® ST 3100 Troubleshooting Procedures Page A-1

Appendix A 800-10680-C, May 2007

AirCell® ST 3100 Troubleshooting Procedures
Symptom Possible Cause Discussion Verification Step(s)

Symptom 3 Possible Cause 3A The ST 3100 Transceiver Verification Test 3A
Handset Display is System antenna does not operates over the Iridium Verify that the system SAT antenna has a clear LOS to the sky in all
illuminated and have Line of Sight (LOS) Satellite Network. When in directions. A clear LOS is defined to exist when there are no obstructions
display indicates view to satellite. coverage the ST system should (such as buildings, trees, vehicles etc) that are higher than 30 degrees
no service detect and register. above aircraft horizon in any direction. This should never be a problem in
If the system does not register, flight.
then it is likely that either the Once the LOS has been established the system should register on the SAT
antenna does not have a LOS to network within 60 seconds. The system is registered when the “NO SVC”
a satellite (3A), or there is a indicator is not visible on the handset display.
problem with the RF channel in If the “NO SVC” indicator extinguishes, then the SAT mode is engaged, and
the aircraft (3B). In this the problem is resolved. The user may choose to make a test call and verify
condition, it is unlikely that there the operation the system.
is a problem with the system If the “NO SVC” indicator stays illuminated, then the system cannot register,
Transceiver. and it is likely that there is an installation or equipment problem. Either
contact AirCell Technical Support for additional guidance, or proceed to
Verification Test 3B.
No Satellite mode Possible Cause 3B Iridium Satellite signal can be Verification Test 3B
signal There is a problem with the monitored using a Personal While the aircraft is on the ground, perform a visual inspection of the ASE
Satellite RF channel. Computer (PC) interface to the system satellite antenna. Verify that the antenna is installed to the aircraft
RS-232 data port that is fuselage in accordance with the system antenna installation drawings.
associated with the Iridium Verify the mechanical integrity of the antenna, and that the antenna is
Channel in question. reasonably free of dirt, oil, ice and other undesired coatings.
Connect a PC using a 9-pin Visually inspect the RF satellite channel, including the coaxial connections to
serial cable to the RS-232 data the antenna and the system Transceiver. Inspect the coaxial connectors to
port of an Iridium channel. verify that they are connected in accordance with the system wiring diagram,
and that they are not damaged. Look for breaks, kinks or other damage to
Using a PC Hyper Terminal the coaxial cable.
connection, (comm 1 or x) (Bits The user is authorized to correct installation errors (such as cabling errors),
set to 19200), at the prompt or to repair minor damage (such as broken coaxial connections, damaged
Enter ate1v1 Enter, then at+csq? coaxial cables, etc). The user is not authorized to open or modify sealed
Enter. Line Replaceable units (LRUs).
This will show a snapshot of If these steps do not resolve the problem, contact AirCell Technical Support
satellite Signal. “+CSQ: X” for additional guidance.
X=bars of signal.
1 to 5, 5 = 5 bars of signal.
Other conditions For all other conditions, contact AirCell Technical Support for guidance.
AirCell® ST 3100 Troubleshooting Procedures Page A-2

Appendix A 800-10680-C, May 2007

AirCell® ST 3100 Instructions for Continued Airworthiness
Design and manufacturing of the AirCell® ST 3100 System allows for “On Condition Maintenance.” On condition maintenance means
that no periodic service requirements are required to maintain continued airworthiness of the system. No maintenance is required until the
equipment does not perform the intended function. Cable harness repair, RF cable maintenance, and antenna replacement can be
accomplished in the field. Refer to Appendix B for detailed information on troubleshooting procedures. Any alteration of this product
voids the FAA or Federal Communications Commission (FCC) certification and the AirCell® warranty. Please consult AirCell® LLC
Technical Support to help evaluate any problem that is not resolved by following the troubleshooting procedures in Appendix B. A Return
Material Authorization (RMA) is required for all repairs or exchanges on items returned to AirCell®. After obtaining an RMA return the
AirCell® ST 3100 components to the factory for repair. If you require a loaner unit to maintain telecommunications operation during
AirCell® repairs, please call Customer Service and request that a serviceable unit be sent to you before removing the installed unit. After
factory repair or receiving the serviceable component, consult the Installation Manual (800-10680) for Post Installation Checkout and
Procedures to verify proper system operation in the aircraft. If component is an Iridium Transceiver, be sure to activate the replacement
serviceable unit (call Customer Service @ 1-888-286-9876) before testing it for operation as the previous Electronic Serial Number (ESN)
/ Phone Number combination will no longer be valid.
AirCell® ST 3100 Instructions for Continued Airworthiness Page B-1

Appendix B 800-10680-C, May 2007

N304JR - ICA AirCell ST 3100 - Telephone

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ST 3100

Installation Manual P/N 800-10680

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Corporate Publications Coordinator

Copyright 2007 AirCell® LLC

uniHub™ is a registered trademark of On-Go, Inc.

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A Original Document October 2002 AirCell®

Revised to delete Handset and Antenna specific

Revised for the addition of the -002 non-POTS

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Figure 2.1. ST 3100 Satellite System Block Diagram ....................................................................2-1

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Table 3.1. Satellite Channel RF Antenna Cable Guide .....................................................................3-5

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Introduction Page 1-1

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1.4 List of Abbreviations and Acronyms

A ampere MTBF Mean Time Between Failures

Introduction Page 1-2

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1.6 List of Related Publications

Publication Publication Number

AirCell® Antenna Installation Manual AirCell® 800-10355

AirCell® Handset Installation Guide AirCell® 800-10055

Environmental Conditions and Test Procedures for Airborne Equipment DO-160D

Introduction Page 1-3

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Introduction Page 1-4

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Figure 2.1. ST 3100 Satellite System Block Diagram

Standard Black Handset (P/N SatelliteTransceiver Standard Iridium Patch

Figure 2.2. ST 3100 Satellite System Standard Components

Description and Operation Page 2-1

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2.2.1. Handset (Standard Handset shown)

The ringer volume is not

To place a call, enter

The PWR button has no function

Figure 2.3. Handset and Cradle

Description and Operation Page 2-2

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The AirCell® ST 3100 is

Figure 2.5. ST 3100 Transceiver Mounting Tray

Description and Operation Page 2-3

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2.2.3. Satellite Patch Antenna (Standard Antenna Shown)

The AirCell® Satellite Patch Antenna is P/N 015-10306-

Figure 2.6. Satellite Patch Antenna

Description and Operation Page 2-4

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3.2. Equipment Location

Installation Procedures Page 3-1

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3.4. Antenna Selection

3.5. Handset Selection

3.6. ST 3100 Transceiver Location

3.7. Power, Handset, and Audio Cabling

3.8. Ring Detect

Installation Procedures Page 3-2

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3.9. Intercom Alert