HGA-7000 High Gain Antenna System

Installation Manual

Document number : 862-A0043_IM

Issue : 8.11
Date : 22 January 2004
Filename : 862-A0043_IM_ISS8.11.DOC

CHELTON Inc.
1720 Lakepointe Drive, Suite 112
Lewisville, Texas 75057
Tel 972-221-1783
Fax 972-436-2716
Email info@cheltoninc.com
Website www.cheltonsatcom.com
 HGA-7000 High Gain Antenna System
Installation Manual

NOTICE
This document is the property of Chelton Inc. hereafter known as Chelton. All rights of copyright are reserved by
Chelton. This document must not be reproduced or used for any other purpose than that for which it was intended
without written permission. Chelton reserves the right to change any information contained in this document without
prior notice. It is the user’s responsibility to ensure that the appropriate issue of this document is being used. While
Chelton has taken every care in the preparation of this document, Chelton does not accept responsibility for loss or
damage alleged to have been suffered arising out of errors or omissions.

CONTROLLED DOCUMENTATION
Notwithstanding the terms of the above Disclaimer, Chelton undertakes in the case of controlled documentation to
supply the Customer with all updates or amendments to this document and furthermore undertakes to notify the
Customer in advance of material changes to the information contained herein. It is the responsibility of the installer
to verify that the most recent issue of this document is being used.

DOCUMENT CHANGE HISTORY

ISSUE DATE DCP DESCRIPTION OF CHANGE

Russ Gordon for content; Brooke Weatherford format & style
8.3 20/June/03
Update to Appendix A as per Chelton redlines
Additions to Appendix A and Section 9.4, inserted new outline
8.4 30/June/03 03/001
drawing
Inclusion of Appendices into Table of Contents and correction
8.5 01/July/03 03/001
of minor typos
8.6 02/July/03 03/001 Correction to numbering, page breaks and figure references
Corrected MSU Alphasoup String; Added Fig12 DLNA,
8.7 17/July/03 03/182
corrected figure numbers & descriptions following Fig 12
BSU and SRU Configuration pin definition update
BSU LED definition added
8.8 28/Aug/03 03/229
Wiring diagrams amended, stating configuration pins are
shown as undefined
8.9 20-Oct-03 03/321 DLNA P/N changes, install configurations.
03/345 Maintenance connectors added to Wiring Diagrams & case
change to lower case in BSU pin-out table. Removed reference
8.10 11-Nov-03 to unnecessary Maintenance Wiring Looms.

03/351 Correction of Alphabet Soup on HGA-7000

8.11 22 Jan 2004 03/395 Wiring updates and configuration pin clarification

DOCUMENT APPROVAL

NAME SIGN DATE

PREPARED H R Braasch
APPROVED B Cobern
APPROVED QA B Griffiths

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SAFETY WARNING

The following general safety precautions must be observed during all phases of operation, service and
repair of this equipment. Failure to comply with these precautions or with specific warnings in this
manual may violate the safety standards of design, manufacture and intended use of the equipment.

RADIATION WARNING

During transmission this system can radiate microwave power from the antenna unit in any direction.
High levels of radio frequency radiation are considered harmful to health. Although all countries have
not agreed upon a single value, the American National Standards Institute (ANSI/IEEE C95.1-1999)
recommends that any person in a controlled environment should not be exposed to radiation stronger than
5 mW/cm2 at the frequencies used in this system. Accordingly, the operator of the system should ensure
that no person should approach within 6.6 feet (2 metres) of the antenna when the system is transmitting,
unless adequate screening is provided.

Despite this warning, specific system configurations may have a much shorter safe distance. This is
dependent on factors like the number of channels used, the use of cooperative channels etc.. Should
shorter safe distances be a requirement in a specific application, please contact Chelton or the
manufacturer of the SDU equipment.

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TABLE OF CONTENTS
PAGE
ABBREVIATIONS......................................................................................................................................................... 8
1 GENERAL ........................................................................................................................................................... 10
2 APPLICABLE DOCUMENTS ............................................................................................................................. 10
3 SYSTEM OVERVIEW ......................................................................................................................................... 11
3.1 HIGH GAIN ANTENNA (HGA-7000) .............................................................................................13
3.2 BEAM STEERING UNIT (BSU-7100)..............................................................................................13
3.3 DIPLEXER/LNA (DAU-7050) .......................................................................................................13
3.4 SATCOM REFERENCE UNIT (SRU-7200).......................................................................................13
3.5 MAGNETIC SENSOR UNIT (MSU-7250) ........................................................................................14
4 INSTALLATION OVERVIEW.............................................................................................................................. 15
4.1 EQUIPMENT REQUIRED .................................................................................................................15
4.2 GENERAL ELECTRICAL REQUIREMENTS .......................................................................................16
4.3 BSU AND SRU MAINTENANCE PORT CONNECTORS ....................................................................16
4.4 STRONG MAGNETIC FIELD WARNING ..........................................................................................17
4.5 ESD WARNING .............................................................................................................................17
4.6 SUMMARIZED INSTALLATION TASKS IN SEQUENCE .....................................................................18
5 HGA-7000 HIGH GAIN ANTENNA INSTALLATION.......................................................................................... 21
5.1 HGA-7000 DESCRIPTION ..............................................................................................................21
5.2 HGA-7000 HIGH GAIN ANTENNA EQUIPMENT REQUIRED ..........................................................24
5.3 HGA-7000 TECHNICAL SPECIFICATIONS .....................................................................................25
5.4 HGA-7000 ELECTRICAL INTERFACES ..........................................................................................26
5.5 HGA-7000 INSTALLATION GUIDELINES .......................................................................................30
5.6 STRUCTURAL MODIFICATIONS .....................................................................................................33
5.7 MOUNTING AND REMOVAL PROCEDURE ......................................................................................34
5.8 HGA-7000 INITIAL CHECKOUT ....................................................................................................37
5.9 HGA-7000 MAINTENANCE, INSPECTION, REPAIR AND SERVICING .............................................37
6 BSU-7100 BEAM STEERING UNIT INSTALLATION ........................................................................................ 41
6.1 BSU-7100 DESCRIPTION...............................................................................................................41
6.2 BSU-7100 BEAM STEERING UNIT EQUIPMENT REQUIRED ..........................................................42
6.3 BSU-7100 TECHNICAL SPECIFICATIONS ......................................................................................42
6.4 BSU-7100 INSTALLATION GUIDELINES........................................................................................43
6.5 BSU-7100 ELECTRICAL INTERFACE .............................................................................................44
6.6 BSU-7100 SOFTWARE SET-UP AND INITIAL CHECKOUT ..............................................................50
6.7 BSU-7100 REPAIR AND SERVICING ..............................................................................................50
7 DAU-7050 DIPLEXER/LNA INSTALLATION ..................................................................................................... 52
7.1 DAU-7050 DESCRIPTION ..............................................................................................................52
7.2 DAU-7050 DIPLEXER/LNA EQUIPMENT REQUIRED ....................................................................52
7.3 DAU-7050 TECHNICAL SPECIFICATIONS .....................................................................................53
7.4 DAU-7050 INSTALLATION GUIDELINES .......................................................................................53
7.5 DAU-7050 ELECTRICAL INTERFACE ............................................................................................54
7.6 DAU-7050 REPAIR AND SERVICING .............................................................................................56
8 SRU-7200 SATCOM REFERENCE UNIT INSTALLATION................................................................................ 58
8.1 SRU-7200 DESCRIPTION...............................................................................................................58
8.2 SRU-7200 SATCOM REFERENCE UNIT EQUIPMENT REQUIRED ...................................................59
8.3 SRU-7200 TECHNICAL SPECIFICATIONS ......................................................................................59
8.4 SRU-7200 INSTALLATION GUIDELINES........................................................................................60
8.5 SRU-7200 ELECTRICAL INTERFACE .............................................................................................62
8.6 SRU-7200 SOFTWARE SET-UP AND INITIAL CHECKOUT ..............................................................68

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8.7 SRU-7200 REPAIR AND SERVICING ..............................................................................................69

9 MSU-7250 MAGNETIC SENSOR UNIT INSTALLATION................................................................................... 71
9.1 MSU-7250 DESCRIPTION ..............................................................................................................71
9.2 MSU-7250 MAGNETIC SENSOR UNIT EQUIPMENT REQUIRED .....................................................71
9.3 MSU-7250 TECHNICAL SPECIFICATIONS .....................................................................................72
9.4 MSU-7250 INSTALLATION GUIDELINES .......................................................................................72
9.5 MSU-7250 ELECTRICAL INTERFACE ............................................................................................73
9.6 MSU-7250 REPAIR AND SERVICING .............................................................................................76
10 COMPASS CALIBRATION PROCEDURE ..................................................................................................... 77
10.1 SOFT AND HARD IRON CALIBRATION.........................................................................................77
10.2 MISALIGNMENT CORRECTION ...................................................................................................78
10.3 REPEATING A COMPASS SWING .................................................................................................79
11 DIAGNOSTICS AND FAULTFINDING ........................................................................................................... 80

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LIST OF FIGURES
PAGE
Figure 1: Block diagram of complete HGA-7000 system...........................................................................12
Figure 2: Top view of HGA-7000 showing optional Protective Boots.......................................................22
Figure 3: Bottom view of HGA-7000 showing optional Protective Boots .................................................22
Figure 4: HGA-7000 Outline Drawing .......................................................................................................23
Figure 5: Close up of HGA-7000 Cable Compartment showing RF (J1) and Control (J2) “pigtails”........26
Figure 6: HGA-7000 Section through the cable compartment showing the RF pigtail connection to the
(color coded blue) RF feed-through TNC connector on the fuselage ..................................................28
Figure 7: Cross section of a typical HGA-7000 installation .......................................................................30
Figure 8: Section through HGA-7000 Mounting Hole ...............................................................................36
Figure 9: BSU-7100 ....................................................................................................................................41
Figure 10: Recommended BSU-7100 mounting orientations .....................................................................43
Figure 11: BSU-7100 Grounding Point ......................................................................................................45
Figure 12: DAU-7050 .................................................................................................................................52
Figure 13: DAU-7050 grounding point.......................................................................................................53
Figure 14: SRU-7200 ..................................................................................................................................58
Figure 15: Recommended SRU-7200 mounting orientations .....................................................................61
Figure 16: SRU-7200 grounding point........................................................................................................64
Figure 17: MSU-7250 .................................................................................................................................71
Figure 18: MSU-7250 grounding point.......................................................................................................74
Figure 19: Aircraft compass swing .............................................................................................................77
Figure 20: Suggested HGA-7000 System interconnect wiring diagram for minimum installation (option
strapping excluded, see Table 7)..........................................................................................................81
Figure 21: Suggested HGA-7000 System interconnect wiring diagram for installation with SRU and MSU
included (option strapping excluded, see Table 7 and Table 16).........................................................82
Figure 22: Suggested HGA-7000 System interconnect wiring diagram for installation with TT HSD++
using SRU with MSU (option strapping excluded, see Table 7 and Table 16). ..................................83
Figure 23: Cross section of various grounding methods.............................................................................85
Figure 24: HGA-7000 Mounting Plate........................................................................................................85
Figure 25: Installation Cross-Sections ........................................................................................................86
Figure 26: Default alignment ......................................................................................................................88
Figure 27: Sample Installation Configurations ...........................................................................................89
Figure 28: Interconnection to TT HSD+ minimum configuration ..............................................................90
Figure 29: Interconnection to TT HSD+ using SRU with MSU in autonomous configuration..................91
Figure 30: Interconnection to OEM SDU using SRU in autonomous configuration..................................92
Figure 31 Interconnection to OEM SDU using aircraft IRS .......................................................................93

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LIST OF TABLES
PAGE
Table 1: Test Equipment Required for HGA-7000 system installation ......................................................15
Table 2: HGA-7000 Equipment Required ..................................................................................................24
Table 3: HGA-7000 Electrical interfaces....................................................................................................27
Table 4: HGA-7000 Inspections and Actions .............................................................................................38
Table 5: BSU-7100 Equipment Required ...................................................................................................42
Table 6: BSU-7100 (J1) Connector Specification.......................................................................................46
Table 7: BSU-7100 Configuration Strap Settings.......................................................................................46
Table 8: Status LED definition ...................................................................................................................47
Table 9: BSU-7100 (J1) Connector Pin-Outs .............................................................................................49
Table 10: DAU-7050 Equipment Required ................................................................................................52
Table 11: DAU-7050 (J4) Panel Mount Connector Specifications.............................................................55
Table 12: DAU-7050 (J4) Connector Pin-Outs...........................................................................................55
Table 13: SRU-7200 Equipment Required .................................................................................................59
Table 14: SRU-7200 (J1) Multi-pin Connector Specifications...................................................................65
Table 15: SRU-7200 (J1) Connector pin-outs.............................................................................................66
Table 16: SRU-7200 Configuration Strap Settings.....................................................................................66
Table 17: GPS data source pin coding ........................................................................................................67
Table 18: Externally Visible LED’s............................................................................................................67
Table 19: MSU-7250 Equipment Required ................................................................................................71
Table 20: MSU-7250 (J1) Pigtail connector ...............................................................................................75
Table 21: MSU-7250 Connector pin-outs...................................................................................................75
Table 22: Chelton Installation Kit...............................................................................................................84

LIST OF APPENDICES
PAGE
Appendix A: Drawings ...............................................................................................................................81
Appendix B: Chelton Installation Kit, 780-A0465 .....................................................................................84
Appendix C: SRU and MSU Reference Axis .............................................................................................87
Appendix D: Typical Installation Configurations .......................................................................................90

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ABBREVIATIONS

ADF Automatic Direction Finder

ADI Attitude Director Indicator
AMO Aircraft Maintenance Organization
Ant Antenna
APU Auxiliary Power Unit
ARINC Aeronautical Radio Inc.
AWG American Wire Gauge
BSU Beam Steering Unit
dB Decibel
DLNA Diplexer/Low Noise Amplifier
EMC Electromagnetic Compatibility
ESD Electrostatic Sensitive Device
FAA Federal Aviation Administration
GHz Gigahertz
GPS Global Positioning System
HGA High Gain Antenna
HSD High Speed Data
IRS Inertial Reference System
kHz Kilohertz
LNA Low Noise Amplifier
MHz Megahertz
MSU Magnetic Sensor Unit
PC Personal computer
PIM Passive Intermodulation
RF Radio Frequency
Rx Received signal
SDM System Definition Manual
SDU Satellite Data Unit
SRU Satcom Reference Unit
STC Supplementary Type Certificate
Tx Transmitted signal
VSWR Voltage Standing Wave Ratio

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1 GENERAL

1) This Installation Manual provides the general installation instructions for the HGA-7000 High Gain
Aero Satcom Antenna System. The HGA-7000 Antenna System conforms to the Inmarsat SDM for
an Aero-H antenna, and is approved for use with Aero-H/H+, and Swift64 HSD Satcom Systems.

2) The standard system consists of the HGA-7000 High Gain Antenna, DAU-7050 Diplexer/LNA, and
the BSU-7100 Beam Steering unit.

3) The optional SRU-7200 Satcom Reference Unit can be installed along with the standard components
to provide for complete stand-alone operation of the Satcom system. Additionally, the optional
MSU-7250 Magnetic Sensor Unit should be installed in instances where the SRU-7200 Satcom
Reference Unit cannot be mounted in a magnetically clean environment.

4) This document does not cover the installation of a complete Satcom System, which includes
installation of an ARINC 741 compliant Satellite Data Unit (SDU) and its associated peripherals. This
document must be used in conjunction with the appropriate Satcom equipment manufacturer’s
installation manual.

5) Specific installation details will have to be derived by the installer for each different aircraft type,
using this manual as a guideline, while adhering to standard aircraft practices and, in particular,
Reference 0 or its equivalent.

2 APPLICABLE DOCUMENTS

AC 43.13-1A/2A, Acceptable Methods, Techniques, and Practices – Aircraft Inspection, Repair

and Alterations, U.S. Dept of Transportation, FAA.
ARINC Characteristics 741P1-9 Aviation Satellite Communications System.
RTCA DO-160D, Environmental Conditions and Test Procedures for Airborne Equipment,
RTCA DO-178B, Software Considerations in Airborne Systems and Equipment Certifications,
December 1 1992
RTCA DO-210D, change level 1, Minimum Operational Performance Standards for
Geosynchronous Orbit Aeronautical Mobile Satellite Services (AMSS) Avionics.
AC 120-90, Operational Approval for Use of Digital Communication Systems.
AC 20-140, Guidelines for Design Approval of Aircraft Data Communication Systems.
AC 23.1309-1C, Equipment, Systems and Installations in Part 23 Airplanes
AC 25-10, Guidance for Installation of Miscellaneous, Non-required, Electrical Equipment.
AC 25.1309-1A, System Design and Analysis
AC 25-21, Certification of Transport Airplane Structure.
OP-036, Protective Boot Fitment – HGA-7000, Omnipless document.
OP-032, Using the HGA-7000 Installation Kit, Omnipless document.

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3 SYSTEM OVERVIEW

1) The purpose of the HGA-7000 Antenna System is to provide an L-band RF link between Inmarsat
Aero-H/H+ and Swift64 HSD Satcom systems and an Inmarsat satellite.

2) The standard HGA-7000 High Gain Antenna System comprises the following subsystems,
interconnected as shown in Figure 1

a) HGA-7000 High Gain Antenna (HGA), part number 677-A0106

b) BSU-7100 Beam Steering Unit (BSU) , part number 677-A0129

c) DAU-7050 Diplexer/LNA (DLNA), part number 677-A0164 (Var 1) or 677-A0167 (Var 2)

3) In cases where the Satcom system cannot access the required data from the aircraft’s Inertial
Reference System (IRS), the following optional subsystems can be added to the HGA-7000 High
Gain Antenna System, also interconnected as shown in Figure 1.

a) SRU-7200 Satcom Reference Unit (SRU), part number 677-A0132

b) MSU-7250 Magnetic Sensor Unit (MSU), part number 677-A0144

4) The optional MSU-7250 should be installed along with the SRU-7200 whenever the SRU cannot be
installed in a magnetically clean environment.

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High Gain Antenna (HGA-7000)

Integrated Phased
GPS Array
Antenna Antenna

RF

Control
(DC,Modem, GPS RF)
28V DC Diplexer/LNA
(DAU-7050)
Control

28V DC
Beam
Steering Unit RX TX
RS232
(BSU-7100) ARINC
429

Satcom
System
Installation RS422 ARINC 429
PC

RS232 Satcom
RS422/ Magnetic
28V DC Reference Power
Sensor Unit
Unit
(MSU-7250)
(SRU-7200)

Figure 1: Block diagram of complete HGA-7000 system

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3.1 High Gain Antenna (HGA-7000)

1) The HGA-7000 High Gain Antenna (HGA) is a low-profile, electronically steered Satcom antenna,
using patented, phased-array beam forming technology. It performs both transmit and receive
functions.

2) It also contains an integrated active GPS antenna providing an amplified GPS signal to a GPS
receiver inside the BSU.

3.2 Beam Steering Unit (BSU-7100)

1) The BSU-7100 Beam Steering Unit (BSU) is a multi-purpose interface unit between an ARINC 741
compliant SDU and the HGA. It receives antenna pointing data from the SDU and sends status data
back to the SDU via an ARINC 429 connection. Between the BSU and the HGA-7000 is a single
lightweight coax cable that carries the same data on a Chelton proprietary modem interface.

2) The coax line also provides power to the HGA and additionally carries amplified GPS RF signals
from the integrated active GPS antenna contained within the HGA-7000. The BSU can forward this
GPS RF source to Satcom systems that contain a GPS receiver in the SDU. The BSU-7100 contains
a GPS receiver. The BSU sends position and velocity measurements to the optional SRU-7200, if
one is installed.

3.3 Diplexer/LNA (DAU-7050)

1) The DAU-7050 Diplexer/LNA (DLNA) separates and combines transmit and receive signals and
amplifies the received signal.

2) Any suitable ARINC 741 compatible DLNA may be substituted for the DAU-7050.

3.4 Satcom Reference Unit (SRU-7200)

1) The SRU-7200 Satcom Reference Unit (SRU) is a multi-sensor unit that is very similar to an IRS
system. It provides the Satcom system with the aircraft attitude, heading, position and velocity
information that is required for beam steering. The SRU-7200 uses its internal sensors to compute
aircraft attitude and heading. It receives GPS postion and velocity from the BSU-7100.

2) The SRU-7200 must be mounted in a magnetically clean environment if it is to use its own internal
magnetomers as a source of heading data.

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3.5 Magnetic Sensor Unit (MSU-7250)

1) The MSU-7250 Magnetic Sensor Unit (MSU) is a compact magnetometer. It is intended for cases
where the SRU-7200 (which also has magnetic sensors) cannot be mounted in a magnetically clean
environment.

2) The MSU is much smaller and less temperature sensitive than the SRU and it is therefore much
easier to find suitable magnetically clean sites for its installation.

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4 INSTALLATION OVERVIEW

4.1 Equipment Required

The following items are not permanently installed on the aircraft as part of the Satcom system but are
required during the installation process.

PART
EQUIPMENT PURPOSE
NUMBER
Used to find a magnetically clean environment in the
Test Magnetometer (MSU) 677-A0144
aircraft.
Installation Support Software Tool Software program required for installation, calibration
800-A0124
for HGA, BSU, SRU & MSU and fault finding. Refer to 870-A0281_CID
Laptop computer with Microsoft
To run the Installation Support Software Tool for HGA,
Windows 98, 2000, XP or higher
BSU, SRU & MSU.
and a RS232 COM port.
Electronic Surface Angle
Protractor accurate to within To determine aircraft and antenna alignment
0.25 degrees

Table 1: Test Equipment Required for HGA-7000 system installation

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4.2 General Electrical Requirements

1) The minimum wire size for power lines is #22 AWG. #24 AWG can normally be used for all other
lines. The installer is however responsible for determining the appropriate wire size required for the
length of cable run, to insure that the specified maximum cable losses do not exceed those indicated
in this manual.

2) Keep the interconnect cables away from circuits carrying heavy current, pulse transmitting equipment
and any other potential source of interference.

3) Use shielded twisted-pair wiring for all balanced connections (RS422 and ARINC 429). Connect
shield grounds to the chassis pins provided in the connectors.

4) The characteristic impedance of each coaxial cable (connectors included) should be 50 ohms with a
VSWR of less than 1.5:1

5) The BSU and SRU both use straps for configuration purposes. Straps are either left open or connected
to ground via the chassis pins on the connectors.

6) There are no discrete outputs, inputs or relay interfaces on the connectors.

4.3 BSU and SRU Maintenance Port Connectors

1) Both the BSU and SRU provide a RS232 maintenance port, which is made available via pins on the
unit’s multi-pin connector. Both of these RS232 maintenance interfaces must be terminated into
female DB9 connectors with pin-outs as defined in female DB9 connectors with pin-outs as defined
in, Figure 21 and Figure 22, to allow for easy connection to a PC serial port.

2) The female DB9 connectors should be located in an easily accessible area to facilitate installation set-
up and trouble-shooting. They do not have to be co-located.

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4.4 Strong Magnetic Field Warning

1) The MSU and SRU both contain sensitive magnetic sensors that can be damaged by exposure to
strong magnetic fields. This damage can occur even if the MSU and SRU are not powered-up.

2) Large transformers, motors, or soldering guns and other high power electrical equipment can produce
high-level AC magnetic fields that can potentially cause damage the MSU and SRU circuitry. High
DC magnetic fields can produce a lingering self-magnetization of the units.

4.5 ESD Warning

1) All of the devices in the HGA-7000 system are ESD sensitive.

2) Standard ESD handling precautions must be observed.

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4.6 Summarized Installation Tasks in Sequence

HGA-7000 installation tasks

Step 1) Choose a site for the HGA based on RF and structural considerations. A suitable
mounting plate will be required.

Step 2) Mount the HGA.

Step 3) Determine or measure the HGA alignment.

BSU-7100 installation tasks

Step 4) Choose a site for the BSU considering temperature and cable lengths.

Step 5) Mount the BSU.

Step 6) Complete HGA to BSU wiring.

Step 7) Perform BSU Checkout and configuration of HGA alignment angles.

DAU-7050 installation tasks

Step 8) Choose a site for the DAU and cable lengths.

Step 9) Mount the DAU.

Step 10) Complete HGA to DAU wiring.

Step 11) Complete HPA to DAU wiring.

Step 12) Complete OEM SDU wiring to DAU.

Step 13) Complete the power and BSU to DAU wiring.

SRU-7200 installation tasks

Step 14) Choose a site for the SRU considering temperature, cable lengths, alignment and
magnetic requirements.

Step 15) Mount the SRU.

Step 16) Install and connect wiring from BSU to SRU.

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Step 17) Determine the x, y, and z distances from the SRU to the GPS antenna in the HGA.

Step 18) Perform the SRU initial checkout and configuration.

MSU-7250 installation tasks

Step 19) Choose a site for the MSU considering alignment and magnetic requirements.

Step 20) Mount the MSU.

Step 21) Install and connect wiring from MSU to SRU.

Step 22) Determine the x, y, and z distances from the SRU to the MSU.

Step 23) Perform the MSU initial checkout and configuration.

Calibration tasks using Installation Support Software Tool

(for systems with MSU and/or SRU only)

Step 24) Perform Artificial /synthetic leveling of SRU (and MSU if one is fitted).

Step 25) Perform the compass swing calibration exercise.

Step 26) Perform the compass misalignment correction exercise.

Final testing (for all configurations)

Step 27) Perform full HGA-7000 system diagnostics check

Step 28) Complete the connection of the HGA-7000 system to the SDU.

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5 HGA-7000 HIGH GAIN ANTENNA INSTALLATION

5.1 HGA-7000 Description

1) The HGA-7000 High Gain Antenna (HGA) is a low-profile, electronically steered Satcom antenna
designed for use with Inmarsat Aero-H, Aero-H+, or Swift64 HSD Satcom systems. It performs both
transmit and receive functions.

2) The HGA-7000 also contains an integrated active GPS antenna providing an amplified GPS signal to
the GPS receiver inside the BSU.

3) The exterior views of the HGA-7000 are presented in Figure 2, and Figure 3, showing the view from
beneath.

4) The detailed outline drawing is presented in Figure 4.

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Figure 2: Top view of HGA-7000 showing optional Protective Boots

Figure 3: Bottom view of HGA-7000 showing optional Protective Boots

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Figure 4: HGA-7000 Outline Drawing

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5.2 HGA-7000 High Gain Antenna Equipment Required

ITEM PART NAME PART NUMBER

1 HGA-7000 Antenna Kit 677-A0106

Contains:
1a o HGA-7000 Antenna
1b o HGA-7000 Mounting Hole Sealing Kit
Contains:
1bi o 8 × Sealing Cap
1bii o 8 × Foam Plug
1biii o 8 × “O”-ring

Installation Dependant and Optional Items

HGA-7000 Installation Kit

2 780-A0465
Contains: (See Appendix B for details)
2a o 1 × Mounting Plate
2b o 8 × Nut Plate Ø5
2c o 8 × Nut Plate Ø4
2d o 1 × HGA-7000 Installation Template
3 HGA-7000 Protective Boot Kit (1) 780-A0516
(1)
Detailed instructions for the use of this kit can be found in Reference 0.

Table 2: HGA-7000 Equipment Required

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5.3 HGA-7000 Technical Specifications

1) Dimensions: 33.90” L x 11.77” W x 1.91” H (861mm x 299mm x 48.4mm)

2) Weight: 19.4 lbs (8.8 kg) maximum

3) Temperature Range: -67°F to +158°F (-55°C to +70° C) (operating)

4) Altitude: Up to 70,000 feet

5) Frequency: 1525 MHz to 1660.5 MHz

6) Coverage: Seamless coverage compliant to Inmarsat SDM

7) Gain: Between 12 and 16 dBiC over 90% of the Inmarsat hemisphere

8) Qualification: Environmental RTCA/DO-160D:

[E1]XABB[U (F,F1)R(C,C1,E,E1)S(L,M)]XSFDFSZXXAC[TY]H[A3E3][2A]AA

9) Qualification: Software RTCA/DO-178B, Level E

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5.4 HGA-7000 Electrical Interfaces

1) The HGA-7000 electrical interfaces to the aircraft are via 2 coaxial ‘pigtail’ cables, which exit from a
compartment underneath the unit at one end. These must be connected to color-coded hermetically
sealed female TNC feed-through connectors that penetrate the fuselage.

Figure 5: Close up of HGA-7000 Cable Compartment showing RF (J1) and Control (J2) “pigtails”

2) DC power (28 VDC nom) can be supplied on either (J1) or (J2) or both. This connection
configuration will be sensed automatically by the HGA-7000 internal circuitry.

3) Power: 28 VDC @ 800mA

4) Minimum operating voltage: 21 VDC

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NO. NAME COLOR CONNECTOR SIGNAL DESCRIPTION

CODING TYPE

J1 Rx: 1525 to 1559 MHz

50 ohm TNC
1. Blue Tx: 1626.5 to 1660.5 MHz, 45W average
(RF) plug (male)
DC: 28 V nom, 20W

J2 Rx: 1.575GHz (GPS)

50 ohm TNC
2. Red Serial: 9600 baud ASK modulated at 210kHz
(Control) plug (male)
DC: 28 V nom, 20W

Table 3: HGA-7000 Electrical interfaces

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5.4.1 HGA-7000 Interconnection to External Units and Fuselage Mounted

Connectors

5.4.1.1 Connectors

Two hermetically sealed feed-through female TNC connectors are required to penetrate the fuselage (see
Figure 1).

1) The feed-through connectors should be color coded with colored heat shrink on both sides to avoid
confusion when connecting. To match the color-coding on the HGA-7000 pigtail coax cables, the RF
cable feed-through connector should be color-coded blue, and the control cable feed-through
connector color-coded red.

HGA-7000 pigtail (1 of 2)

Cable compartment
HGA-7000 antenna

Color coded feed

through

Internal cable (low loss

for RF line)

Figure 6: HGA-7000 Section through the cable compartment showing the RF pigtail connection to the
(color-coded blue) RF feed-through TNC connector on the fuselage

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5.4.1.2 Electrical Characteristics of the HGA/ DLNA Interconnection

1) The recommended combined loss of the cable and feed-through TNC connector is 0.3 dB or less.

2) The performance of the HGA-7000 is such that slightly higher loss (up to 0.8dB) can be
accommodated depending on the system configuration. Consult Chelton or the Satcom system
manufacturer for support in this regard.

3) The cable connectors shall satisfy Passive Inter-modulation (PIM)

PIM < -190dBc at the following frequencies:
1558 MHz, 1549 MHz, 1540 MHz and 1531 MHz.
For a two tone test where:
f 1 = 1630 MHz @ 43.5dBm
f 2 = 1639 MHz @ 43.5dBm

5.4.1.3 Maximum coax cable loss between HGA and BSU

1) The coax cable must have an insertion loss of less than 18 dB at 1575 GHz and DC resistance of less
than 7 ohms.

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5.5 HGA-7000 Installation Guidelines

Important Note:
The specific design of the installation of the HGA-7000 onto the fuselage is the
responsibility of the installer.

5.5.1 General
1) The HGA-7000 must be mounted on the top of the fuselage as it communicates with satellites.

2) The installation must provide adaptation of the flat underside of the HGA-7000 to the curvature of the
fuselage. The cross section of a typical installation is shown in Figure 7. Appendix B and Reference
0 provide further details for installation using the Chelton supplied HGA-7000 Installation Kit.

3) Two hermetically sealed feed-through female TNC connectors are required to penetrate the fuselage,
and therefore must be incorporated into the mechanical design of the installation. Please see Section
5.4 for connector details.

4) The HGA-7000 is fixed to the fuselage by means of 8 bolts, which are accessed from the outside.

5) The mounting-hole dimensions are given in Figure 8. The bolts must have a minimum tensile strength
of 2450 lb (10000N).

6) An HGA-7000 Installation Template (part number 478-A1879) is available from Chelton to aid in
planning the installation on the fuselage. It is a transparent Mylar sheet providing the footprint,
mounting hole and connector positions, and cable installation angles. The template can be overlaid
on the fuselage and used as a positioning guide for the fuselage penetrations.

Sealing Kit (Cap, Foam Plug

and O-ring) supplied. Apply
Si RTV to thread
#10-32 bolt for mounting (8
places)
Do not apply sealant. O ring
in antenna base provides the
seal

Seal interface between HGA and

Mounting Plate with bead of flexible
sealer in recess
Seal and fair interface between Mounting
Plate and airframe with fillet of flexible
sealer

Mounting Plate
External doubler plate Fix adaptor plate to fuselage
(wet installed)
Apply sealant at all contact
areas between Mounting Sealed anchor nut
Plate and fuselage to
prevent fretting and
moisture entrapment

Figure 7: Cross section of a typical HGA-7000 installation

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5.5.2 Mounting Considerations

1) Correct mounting of the HGA-7000 on the aircraft is crucial for good performance of the system.
2) The factors that influence the final position are listed in the following paragraphs:

5.5.2.1 Alignment

1) The HGA-7000 must be installed with its long axis facing fore/aft. The default orientation is with the
cable compartment to the front, but it can be mounted the opposite way to facilitate improved routing
of the cables in the aircraft. When the HGA is rotated 180 degrees to locate the cable compartment to
the rear, make sure the Chelton or installer-fabricated radius mounting plate remains in the original
fore-aft orientation for proper drain slot positioning.

2) The HGA-7000 can also be mounted slightly off center, or with a slight nose up or nose down
attitude.

3) Misalignment, intentional or otherwise, of the HGA is accommodated for by software in the BSU.
The BSU requires the azimuth alignment of the antenna with respect to the longitudinal axis, and the
roll and pitch alignment relative to the aircraft’s horizontal reference. These three angles need to be
determined to an accuracy of 0.25 degrees.

4) The roll and pitch alignment of the antenna can be determined by subtracting the aircraft attitude
angles from the antenna attitude angles (relative to the same local level). The aircraft attitude angles
can be read from the ADI or measured with an electronic surface angle protractor on an appropriate
reference surface. The antenna attitude angles can be measured on the radius mounting plate before
the antenna is mounted.

5) These three angles define the installation alignment of the HGA and will be stored in EEPROM on
the BSU to be used as part of its beam steering calculations. It will be recorded with the date and
time of installation and an aircraft identification number, such as an ICAO or tail number. The
installation software will guide the installer through the process of entering the information.

5.5.2.2 Lightning Strike

1) The HGA-7000 is rated for use in Zone 2A – swept strike zone.

5.5.2.3 RF Blockage

1) The tail plane and ventral strake may cause a small amount of blockage of the RF beam.

2) To minimize RF blockage, the HGA-7000 should be placed at least 10ft (3m) forward of the base of
the tail plane in the case of smaller aircraft (less than 12,500lb (5,700kg), and a greater distance in the
case of larger aircraft.

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5.5.2.4 Co-location with other Antennas

1) The HGA-7000 has passed the recommended RTCA/DO-160D Radiated Emission tests with margin.
However, transmission from the HGA-7000 may still affect the operation of other RF systems in
particular cases. It is the responsibility of the installer to evaluate this before deciding on the
mounting position of the HGA-7000.

2) The systems most likely to be affected by direct high power transmission are GPS and other Satcom
systems, such as Globalstar and Iridium.

3) A minimum distance of 12 - 15 inches between antennas is recommended.

5.5.2.5 Fuselage Structure

1) 8 mounting holes and 2 connector holes must be provided for.

5.5.2.6 Engines and APU Inlets

1) The HGA-7000 must be positioned out of the zone of influence of the engines and APU inlets. This
must be verified by the installer.

5.5.2.7 Ground Plane

1) The HGA-7000 requires a ground plane, usually the aircraft fuselage, to operate properly. The
ground plane should nominally extend at least 8 inches (0.2 m) around the antenna perimeter.

2) The installer must ensure the 8 bonding points at the base of the mounting holes are in electrical
contact with the airframe. The mounting bolts themselves can also be used for bonding. In the case of
a non-conductive composite structure, the installer must make provision for a ground plane.

3) Chelton should be consulted for center engine and tail cap installations.

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5.6 Structural Modifications

5.6.1 Structural Loads

1) Structural modifications have to be made to the aircraft in order to accommodate the extra flight loads
and mass of 19.4 lbs. (8.8kg), as well as to adapt the flat underside of the HGA-7000 to the curvature
of the aircraft’s fuselage. This is the responsibility of the installer.

2) The HGA-7000 has been designed with eight mounting holes for attachment to the airframe.

3) The effect of the increased loading on the fuselage is airframe specific. A structural analysis must be
performed to determine what structural modifications to the airframe are required prior to installing
the HGA-7000.

5.6.2 Mounting Plate

1) Some fabricated construction or mounting plate will be required in most cases to adapt the curved
airframe to the flat antenna base. If the construction results in water traps, suitable drainage and anti-
corrosion measures must be taken in these areas.

2) To simplify installations, an installation kit (part number 780-A0465) can be purchased from Chelton.
The main component of the kit is a Mounting Plate that adapts the curvature of the fuselage to the flat
underside of the antenna. The installation kit is available in different versions to suit most aircraft
types. See Appendix B for more information on the Installation Kit and its application.

5.6.3 Painting

1) The metallic segments on the lightning diverter strips must never be painted.

2) If minor paint touch-ups or repainting of the radome is required, please consult Chelton.

5.6.4 Sealing Underside and Filleting

1) The HGA-7000 is sealed and therefore no special precautions have to be taken for sealing of the
antenna itself. The base of the antenna is painted except at the grounding areas.

2) The installer must take suitable precautions to prevent water from becoming trapped below the HGA-
7000.

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5.6.5 Grounding

1) The requirement for grounding resistance between the unit and the fuselage is ≤ 2.5mΩ.

2) There are three methods of grounding the unit.

a) The first is via direct grounding of the base plate in the area around the mounting bolts.
b) The second is via the mounting bolts and grounded fuselage anchor nuts.
c) The third method is via a dedicated grounding screw hole directly into the antenna base plate,
located in the cable compartment area.
• Direct Bonding Method:
a) An annular area with an outer diameter of Ø0.63” (Ø16.4mm) is provided around each of the
8 mounting holes for direct bonding. These areas are Alodined Aluminum and are grounded
to the rest of the base plate. The corresponding area on the fuselage or mounting construction
must be bared of paint before the antenna is attached.
b) Check that the “O” rings around the 8 (mounting hole) bonding areas of the antenna are in
place before securing the antenna.
• Mounting Holes:
a) The metal inserts inside the mounting holes are ‘316’ stainless steel and are grounded to the
base plate of the antenna.
b) The mounting hole can be used as a ground if the anchor nuts are properly grounded.
• Ground Screw:
a) A ground screw hole has been provided inside the cable compartment area. The thread is #8-
32 UNC, with 3/8” (9.5mm) full depth thread.

5.7 Mounting and Removal Procedure

5.7.1 Limitations and Alignment

1) The fore/aft axis shall be measured to within ±0.25° of the aircraft’s longitudinal axis and the roll and
pitch angles measured to within ±0.25°.

2) The mounting interface surface shall be flat to within ±0.02 inches (±0.5mm) over the full surface and
to within ±0.012 inches (±0.3mm) over any 3.96 inches (100mm) length.

3) The maximum rated speed is 355 KEAS, Mach 0.92. At this speed the antenna is well within its
structural limits, and therefore, more extreme flight envelopes are possible. Contact Chelton for more
information.

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5.7.2 Mounting Procedure

1) If the grounding method is by means of a ground wire attached to the hole provided in the cable
compartment, this wire should be attached to the antenna at this point.

2) Position the HGA-7000 over the mounting holes and tilt approximately 30° to 45° to the left.

3) Connect the RF pigtails to the feed-through TNC connectors mounted on the fuselage. Ensure that
they are aligned such that they will fit in the hollow provided in the base plate. Tighten to a
maximum of 0.7ft/lb (1Nm). Ensure that the color codes of the pigtails and feed-through connectors
match.

4) Attach the free end of the ground wire (if used) to the fuselage.

5) Check that the O-rings are in place on the base around the mounting holes.

6) Align the HGA-7000 with the mounting holes. Insert the mounting bolts and torque down evenly to
2.6-3.7ft/lb (3.5 - 5Nm). The torque sequence should be from the center outwards to the ends. See
installation drawing Doc No. 677-A0106_ID for locating dimensions.

CAUTION: If the mounting bolts are too long, there is the risk of possible breach of
the pressure vessel of the aircraft, as the sealed anchor nut covers will be ruptured. The
required bolt length can either be ascertained by calculation or by lightly screwing in a bolt
until it bottoms. Measurement of the free length above the fuselage will determine if a longer
or shorter bolt is required.

7) Verify the ground resistance is ≤ 2.5mΩ

8) Apply a fillet around the rim to seal the interface of the base of the HGA-7000 to the fuselage. This
fillet must not extend onto the radome.

9) If the fillet sealing is to be painted the radome must be masked during the process.

10) Check that the O-ring is in place on the sealing cap. Insert the foam plugs into the cap and coat the
threads with a neutral cure RTV Silicone. Tighten the sealing caps. Caps, plugs and O-rings must not
be re-used. See Figure 8.

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S ealing C ap

O -R ing
M O U N T IN G H O LE
S E A LIN G K IT F oam P lug

0.957" [24.300mm]
Ø 0.387" [Ø 9.830m m ]

0.205" [5.200m m ]
O -R ing
A lodine A l (ground)

Figure 8: Section through HGA-7000 Mounting Hole

5.7.3 Removal Procedure

1) The filleting and sealing will have to be cut away to release the HGA-7000 from the aircraft.

2) The removal procedure is the reverse of the mounting procedure.

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5.8 HGA-7000 Initial Checkout

1) The HGA-7000 can only be tested once a BSU-7100 Beam Steering Unit is connected.

2) Design and install the full cable loom as applicable to your installation into the Aircraft.

3) Ensure that the loomed maintenance connectors are mounted in accessible locations.

4) Connect the BSU-7100 and the HGA-7000 to the applicable ports on the loom.

5) Connect a PC via the Female DB9 RS232 connector to the BSU maintenance port connector on the
loom.

6) Power the System.

7) Run the Installation Support Software Tool (Part number: 800-A0124). Follow the on-screen
prompts.

5.9 HGA-7000 Maintenance, Inspection, Repair and Servicing

5.9.1 Maintenance

1) The HGA-7000 does not require maintenance or adjustment. However, periodic removal for
inspection of corrosion should be performed in accordance with the FAA approved (or governing
regulatory agency) Instructions for Continued Airworthiness for the installation.

5.9.2 Inspection and Actions

1) The inspection interval is equal to the Mandatory Periodic Inspection interval for the aircraft type on
which it is fitted or 600 hours, whichever is shorter.

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INSPECTION ACTION

1. Check that the protective boots are in

Replace boots if damaged.
place if they were previously installed
2. Check the radome for cracks, paying
particular attention to the area around the
If cracks are present, remove and return the HGA-
mounting points and to the interface of
7000 to Chelton for inspection and repair.
the radome dielectric and the antenna
base.
If no evidence of moisture or corrosion is found,
proceed to inspection Item 4.
3. Remove Seal Caps and Foam Plugs from
mounting bolt recesses. Check for
moisture and corrosion. If there is any moisture or corrosion found in the
[Note: A new Mounting Hole Sealing Kit mounting holes or on the mounting bolts, remove
antenna, and inspect the airframe below the antenna
(p/n 780-A0484) will be required to
for corrosion. Remove any corrosion and protect
reinstall the antenna.]
according to the airframe manufacturers approved
procedures.
Re-tighten the screws as necessary to obtain proper
4. Check that the HGA-7000 is securely
torque figure. See Item 6) of 5.7.2 (Mounting
fastened to the fuselage
Procedure) to obtain proper torque procedure.

If resistance is less than 2.5mΩ, proceed to Item 6.

5. Measure resistance from the base plate of

the HGA-7000 to the fuselage. If resistance exceeds 2.5mΩ, remove the HGA-7000
Resistance must be less than 2.5mΩ. from the aircraft, and refurbish all grounding points.
Remount antenna per Section 5.7.2 of this
installation manual.

6. Install new Mounting Hole Sealing Kit Follow instructions in Section 5.7.2 of this
(p/n 780-A0484) installation manual.

Table 4: HGA-7000 Inspections and Actions

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5.9.3 Built-In Tests (BITE)

1) Faulty units are identified via the various levels of internal BITE that provide alarms and error codes.
The accessing of these messages is via the RS 232 interface of the BSU. In addition, some error
messages may be accessed through the Satcom system, depending upon the system to which the
HGA-7000 is connected.

2) Faulty units must be returned to Chelton for repair.

5.9.4 HGA-7000 Repair and Servicing

1) The only repair actions that can be performed in the field are:

a) Repairing paintwork (minor cosmetic touch-up)

b) Replacing optional protective boots

2) Consult Chelton for the appropriate instructions regarding protective boot and paint repair.

5.9.5 Warranty Seal

1) Warranty will be void if the "Warranty Seal" on any unit is removed or damaged.

5.9.6 Storage and Transportation

1) The HGA-7000 is ESD sensitive and standard ESD handling precautions must be observed.

2) The units must be placed in an anti-static bag inside a padded box. The box must be stored in a dry
area (<50%RH) where the temperature does not exceed –40°F to +185°F and (–40°C and +85 °C).

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Figure 9: BSU-7100

6 BSU-7100 BEAM STEERING UNIT INSTALLATION

6.1 BSU-7100 Description

1) The BSU-7100 Beam Steering Unit is the primary interface between the Satcom system SDU and the
HGA-7000 High Gain Antenna.

2) The BSU-7100 connects to the Satcom system via an ARINC 429 interface, translating the ARINC
741 antenna control commands to the Chelton proprietary modem interface. Once translated, the BSU
is able to electronically steer the HGA through a single lightweight coax cable that also carries DC
power to the HGA.

3) GPS RF signal from the active GPS antenna inside the HGA-7000 is also carried on the same coax
cable. The BSU-7100 contains a 12-channel GPS receiver and it communicates GPS information to
the SRU-7200 via an RS 422 interface.

4) HGA and BSU status information is reported back to the SDU via ARINC 429.

5) The BSU-7100 is also the primary interface between the complete HGA-7000 system and the PC for
configuring and testing. The BSU communicates with the PC through a RS 232 interface.

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6.2 BSU-7100 Beam Steering Unit Equipment Required

PART NAME PART NUMBER QUANTITY

BSU-7100 Beam Steering Unit 677-A0129 1
BSU-7100 Connector Kit MS3126F22-55S or 1
MS3476L22-55S or
MS3476W22-55S.

Table 5: BSU-7100 Equipment Required

6.3 BSU-7100 Technical Specifications

1. Dimensions: 7.56” L x 6.38” W x 1.95” H (192mm x 162mm x 49.5mm)

2. Weight: 3.3 lbs (1.5 kg) maximum

3. Temperature Range: -67°F to +158°F (-55°C to +70° C) (operating),

-40° F to + 158° F (-40°C to +70°C) (when using GPS)

4. Altitude: Up to 70,000 feet

5. Qualification: Environmental RTCA/DO-160D:

[C4]XABB[U(F,F1)R(C,C1,E,E1)]S(L,M)]EWFXFXZ[B,A]AAC[TT]H[A3E3]XAA

6. Qualification: Software RTCA/DO-178B, Level E

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6.4 BSU-7100 Installation Guidelines

6.4.1 Alignment Requirements

1) The BSU must be mounted to prevent water or droplets running directly into the drainage holes on the
side plates.

Figure 10: Recommended BSU-7100 mounting orientations

2) Apart from considerations of drainage and temperature as described above, the alignment and
position of the BSU is not significant to the functioning of the system. Unlike the HGA, SRU and
MSU, no alignment calibration is required for the BSU.

6.4.2 Mounting Requirements

6.4.2.1 Mounting Structure

1) Mount the BSU to a rigid structure that will ensure the DO-160D vibration envelopes for the unit are
not exceeded. See Paragraph 6.3 for the DO-160D environmental categories string.

6.4.2.2 Mounting Fasteners

1) To fasten the unit onto the aircraft, use four 10-32 UNF or M5 stainless steel screws, washers and
nuts.

2) Care must be taken not to block any of the drainage holes.

3) See installation drawing Doc No. 677-A0129_ID for locating dimensions.

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6.5 BSU-7100 Electrical Interface

1) Power: 28 VDC @ 1.8AMPS

2) Minimum operating voltage: 18 VDC

6.5.1 Electrical Installation Guidelines

1) The BSU interfaces to Satcom system equipment via an ARINC 429 interface. Although the interface
does not mechanically comply with the ARINC 741 standard, the signaling and protocol used are
fully compliant.

2) The installer needs to strap Pin M to Pin h of the connector to apply 28 VDC power to the HGA
coaxial output J3.

3) Keep the interconnect cables away from circuits carrying heavy current, pulse transmitting equipment
and any other potential source of interference.

4) Use shielded twisted-pair wiring for all balanced connections (RS422 and ARINC 429). Connect
shield (signal) grounds to the chassis pins provided in the connectors.

5) When designing the wire harness, keep the power grounds separate from the signal grounds and
connect them to the appropriate provided aircraft grounding points.

6) Please refer to the specific Satcom system manufacturer’s installation manual for interconnect
requirements, and to determine if a BSU-7100 is required as part of the installation.

6.5.2 BSU-7100 Maintenance Port Connectors

1) The BSU-7100 provides a RS232 maintenance port, which is made available via pins on the unit’s
multi-pin connector. This RS232 maintenance port must be terminated into a female DB9 connector
to provide for the required connection to a PC serial port.

2) The female DB9 connector should be located in an easily accessible area to facilitate installation set-
up and trouble shooting.

3) In installations that do not use the beam steering unit, reference should be made to the equipment
manufacturers documentation for access to the HGA-7000 maintenance data.

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6.5.3 Maximum Power Cable Distance between BSU and Aircraft Power Source

1) The maximum current drawn (in-rush current included) from the aircraft power source is 1.8 Amps.
The minimum operation voltage, at which switch-off occurs, is 18 Volts.

2) The total supply source impedance, including the supply cable, must not allow the voltage at the BSU
to drop below 18 volts at switch-on.

6.5.4 Maximum Cable Distance between BSU and SDU

1) The maximum ARINC 429 cable distance is 170ft (57m). Refer to the wire gauge guideline in
Paragraph 4.2.

6.5.5 Maximum Cable Distance between BSU and SRU

1) The maximum RS422 cable distance is 3,900ft (1200m). Refer to the wire gauge guideline in
Paragraph 4.2.

6.5.6 Grounding Requirements

1) There is a tapped grounding point provided located at the rear of the BSU base plate.

2) Connect this to aircraft ground with a resistance ≤ 2.5 mΩ. See Figure 11.

10 – 32 UNF
Tapped Grounding
Hole

Figure 11: BSU-7100 Grounding Point

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6.5.7 BSU-7100 (J1) Multi-pin connector:

Specification Number: MS3112E22-55P

Shell Style: Square Flange Receptacle (02)
Service Class: E
Shell Size: 22
Insert Arrangement: 55
Contact Configuration: P (Male)
Contact Type: Straight spills (PCB mounting) diameter 0.76mm
Insert Rotation: Normal (no rotation)
Materials / Finish: MIL-C-26482 Series 1
Suggested Mating Connector: MS3126F22-55S or
MS3476L22-55S or
MS3476W22-55S

Table 6: BSU-7100 (J1) Connector Specification

6.5.8 BSU-7100 Configuration Strap Settings

The BSU-7100 uses straps for configuration purposes. Straps are either left unconnected or connected to
ground via the chassis pins on the connectors.

Configuration
Description Unconnected Connected to ground
Input #
SRU absent and GPS optional.
If an internal GPS is detected, its
SRU-7200 and
1 Both are present. data bytes are forwarded to the
internal GPS engine.
SRU RS422 port but warnings are
not reported for incorrect operation.
ARINC 741 compliant
2 SDU type TT HSD+ SDU
Satcom SDU
3 ARINC 741 DLNA Present Not present
4 Antenna type 5V GPS Antenna 28V Satcom Antenna
Not used. Pins can be
5-7 Not applicable Not applicable
left unconnected
Must be configured so that number of pins connected to
8 Parity bit
ground is odd

Table 7: BSU-7100 Configuration Strap Settings

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6.5.9 LED definitions

The LED’s provide a simple visual check of the status of the BSU.
.
LED1 LED2 LED3
Colour Green Green Red
Indicate the
Indicate the CPU Indicate the BSU BITE
Purpose availability of
software state status
input power
Label POWER CPU BITE

LED STATE
Initially, 2 second
Initially, 2 second LED
LED test at start-
test at start-up.
up.Afterwards if
ON Power available Afterwards, if
permanently ON,
permanently ON,
DSP in FINE
DSP not running
OPERATION state
DSP initializing or
not fully High-level critical
Flashing fast
Unused operational BITE failure.
(5 Hz)
(e.g. power save (e.g. software error)
mode)
Toggle:
Flashing slow
Unused DSP in SW DOWNLOAD state
(0.5 Hz)
- boot-loader firmware running
DSP software not
OFF Power off BITE OK
running

Table 8: Status LED definition

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6.5.10 BSU-7100 (J1) Connector pin-outs:

PIN SIGNAL DESCRIPTION: COMMENT
A RS422 Rx OEM Input B
B RS422 Rx SRU/MSU Input A
C RS422 Rx SRU/MSU Input B
D RS422 Tx OEM Output B
E RS422 Tx SRU/MSU Output A
F RS422 Tx SRU/MSU Output B
G GPS time mark Output B
H ARINC429 (A) Tx Output A Connect to SDU Bite Input A
J ARINC429 (A) Tx Output B Connect to SDU Bite Input B
K ARINC429 (B) Tx Output B
L DLNA Control Output Connect to DLNA (J4 Pin B)
This must be strapped to Pin H of this
M Antenna Power Input connector to apply +28VDC power to the
HGA coaxial output (J3)
N Antenna Power Output 5V
P MSU +28V DC Ground Return
R MSU +28V DC Output
S +28V DC Input Connect to aircraft power (+28VDC)
Maintenance RS232 port PC connector
T RS232 Rx Input
Pin 3
Maintenance RS232 port PC connector
U RS232 Tx Output
Pin 2
V RS422 Rx OEM Input A
W ARINC429 (A) Rx 1 Input A Connect to SDU Multi - Control Output A
X ARINC429 (A) Rx 1 Input B Connect to SDU Multi - Control Output B
Y RS422 Tx OEM Output A
Z ARINC429 (A) Rx 2 Input B
a ARINC429 (B) Rx 1 Input A
b GPS time mark Output A
c ARINC429 (B) Rx 2 Input A
d ARINC429 (B) Rx 2 Input B
e ARINC429 (B) Tx Output A
f Configuration Input #1
g Configuration Input #2
This must be strapped to Pin M of this
h Antenna Power Output 28V connector to apply +28VDC power to the
HGA coaxial output (J3)
i Configuration Input #4
j Configuration Input #5
Connect to aircraft Ground (+28VDC
k +28V DC Ground Return
return)
m Configuration Input #7
n Configuration Input #8

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p Chassis
q Chassis
r ARINC429 (A) Rx 2 Input A
s Future spare
t ARINC429 (B) Rx 1 Input B
u Future spare
v DLNA BITE Input Connect to DLNA (J4 Pin H)
w Future spare
x Configuration Input #3
Y Future spare
z Configuration Input #6
AA Chassis
BB Chassis
CC Chassis
DD Chassis
EE Chassis
FF Chassis
GG Chassis
HH Chassis

Table 9: BSU-7100 (J1) Connector Pin-Outs

6.5.11 BSU-7100 (J2) coaxial connector:

1) Purpose: Additional GPS RF signal

2) Type: Bulkhead, female, TNC
3) Suggested mating connector: Straight, male, TNC Suhner TNC-60-3-9/133

6.5.12 BSU-7100 (J3) coaxial connector:

1) Purpose: Connect to HGA power/modem/GPS port

2) Type: Bulkhead, female, TNC
3) Suggested mating connector: Straight, male, TNC Suhner TNC-60-3-9/133

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6.6 BSU-7100 Software Set-up and Initial Checkout

1) With the BSU powered and the PC connected, run the Installation Support Software Tool and follow
the on-screen prompts.

2) The alignment angles of the HGA must be entered into the Installation Support Software Tool. They
will be written to the EEPROM of the BSU and used to apply corrections to the antenna pointing.

6.7 BSU-7100 Repair and Servicing

6.7.1 Built-In Test (BITE)

1) Faulty units are identified via the various levels of internal BITE that provide alarms and error codes.
The accessing of these messages is via the RS 232 interface of the BSU and if installed, the SRU. In
addition, some error messages may be accessed through the Satcom system, depending upon the
system to which the HGA-7000 is connected.

2) Faulty BSU-7100 units must be returned to Chelton for repair.

6.7.2 Warranty Seal

1) Warranty will be void if the "Warranty Seal" on any unit is removed or damaged.

6.7.3 LED’s
1) The green LED labeled “POWER” will be illuminated when the device is powered up.

2) The green LED labeled “CPU” indicates the software state. It will be on when the device is running
normally. It will flash quickly (approx 0.5 seconds) while the device is initializing, or in a functional
test state or in some form of degraded condition. It will flash slowly (approx 2 seconds) when the
system is in a software download mode.

3) The red LED labeled “BITE” will normally be off. It will flash if an error has been detected.

4) All of the LED’s will be on for approximately 2 seconds at startup.

6.7.4 Storage and Transportation

1) The BSU-7100 is ESD sensitive and standard ESD handling precautions must be observed.

2) The units must be placed in an anti-static bag inside a padded box. The box must be stored in a dry
area (<50%RH) where the temperature does not exceed -67 °F and +185 °F (-55°C to +85 °C).

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ANTENNA
CONNECTOR

Figure 12: DAU-7050

7 DAU-7050 DIPLEXER/LNA INSTALLATION

7.1 DAU-7050 Description

1) The DAU-7050 Diplexer/LNA (DLNA) separates transmit and receive signals, and amplifies the
received signal.

2) The 677-A0167 (VAR-2) is the preferred version of the diplexer as it gives greater protection to the
Iridium band.

3) Another ARINC 741 compatible DLNA may be substituted for the DAU-7050.

7.2 DAU-7050 Diplexer/LNA Equipment Required

PART NAME PART NUMBER QUANTITY

677-A0164 (Var1) or
DAU-7050 Diplexer/LNA 1
677-A0167 (Var2)
DAU-7050 Connector Kit MS3126F12-10S or 1
MS3476L12-10S or
MS3476W12-10S

Table 10: DAU-7050 Equipment Required

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7.3 DAU-7050 Technical Specifications

1) Dimensions: 11.00” L x 7.75” W x 1.85” H (280mm x 197mm x 47mm)

2) Weight: 6.5 lbs (2.95 kg)

3) Temperature Range: -67°F to +158°F (-55°C to +70° C) (operating),

4) Altitude: Up to 55,000 feet

5) Qualification: Environmental: RTCA/DO-160D

[F2X]AC[CD][S(E,L,M,Y)U(F,F1)][E,H]RFXFXZZAZC[WWP]H[A3E4]XXA

7.4 DAU-7050 Installation Guidelines

7.4.1 Alignment and Mounting Requirements

There are no special alignment or mounting requirements for the DAU.

Rx CONNECTOR

GROUNDING Tx CONNECTOR
POINTS

POWER CONNECTOR

Figure 13: DAU-7050 grounding point

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7.5 DAU-7050 Electrical Interface

1) Power: 28 VDC @ 150mA or 115VAC, 400Hz @ 100mA RMS

2) Minimum operating voltage: 21 VDC

7.5.1 Electrical Installation Guidelines

1) When designing the wire harness, keep the power grounds separate from the signal grounds and
connect them to the appropriate provided aircraft grounding points.

7.5.2 Maximum Cable Distance between DLNA and HGA

1) The recommended combined loss of the RF cable and feed through connector is 0.3dB or less.

2) The performance of the antenna is such that higher loss can be accommodated. Chelton or the Satcom
system manufacturer is to be consulted for support in this regard.

7.5.3 Maximum Power Cable Distance between DLNA and Aircraft Power Source

1) The maximum current drawn (inrush current included) from the aircraft power source is as stated in
paragraph 7.5. The minimum operation voltage at which switch-off occurs is also stated in paragraph
7.5.

2) The combined power-line and ground return series resistance must therefore be chosen to prevent the
voltage at connector (J1) to fall below the DLNA switch-off voltage of 21 VDC.

7.5.4 Maximum Rx and Tx Cable Distance between DLNA and SDU

1) This is dependent on the Satcom equipment. Refer to the OEM’s Satcom system installation manual.

7.5.5 Maximum Cable Distance between DLNA and BSU

1) The combined resistance of the “LNA ON/OFF Control” and “LNA BITE / CONTROL GROUND”
lines must not exceed 10 ohms.

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7.5.6 Grounding Requirements

1) Keep the (J4) connector chassis power ground (Pin A) separate from the signal ground (Pin K).

2) Connect the chassis power ground to an appropriate aircraft grounding point.

7.5.7 DAU-7050 Multi-Pin Connector (J4):

Specification Number: MS3112E12-10P

Shell Style: Square flange receptacle (02)
Service Class: E
Shell Size: 12
Insert Arrangement: 10
Contact Configuration: P (Male)
Contact Type: Solder
Insert Rotation: Normal (no rotation)
Materials / Finish: MIL-C-26482 series 1
Suggested Mating Connector: MS3126F12-10S or
MS3476L12-10S or
MS3476W12-10S

Table 11: DAU-7050 (J4) Panel Mount Connector Specifications.

7.5.8 DAU-7050 (J4) Connector Pin-outs

PIN SIGNAL DESCRIPTION COMMENT

A Chassis Ground
B LNA ON/OFF Control Connect to BSU (J1 Pin L)
C Spare
D Spare
E 115VAC, 400Hz COLD
F 115VAC, 400Hz HOT
G +28VDC HOT Aircraft power (+28VDC)
H LNA BITE Connect to BSU (J1 Pin v)
J LNA BITE / CONTROL GROUND Connect to BSU (J1 Pin AA)
K +28VDC RETURN Aircraft power (+28VDC return)

Table 12: DAU-7050 (J4) Connector Pin-Outs

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7.5.9 ANT Coaxial connector

1) Purpose: Interconnect to main RF port of HGA-7000 (J1)

2) Type: TNC female
3) Suggested mating connector: Straight, male, TNC Suhner TNC-60-3-9/133

7.5.10 Tx Coaxial connector

1) Purpose: Interconnect to SDU Tx port

2) Type: N-type female

7.5.11 Rx Coaxial connector

1) Purpose: Interconnect to SDU Rx port

2) Type: TNC female
3) Suggested mating connector: Straight, male, TNC Suhner TNC-60-3-9/133

7.6 DAU-7050 Repair and Servicing

7.6.1 BITE

1) Faulty units are identified via the various levels of internal Built-In Tests (BITE) that provide alarms
and error codes. The accessing of these messages is via the RS 232 interface of the BSU and if
installed, the SRU. In addition, some error messages may be accessed through the Satcom system,
depending upon the system to which the HGA-7000 system is connected.

2) Faulty DAU-7050 units must be returned to Chelton for repair.

7.6.2 Warranty Seal

1) Warranty will be void if the "Warranty Seal" on any unit is removed or damaged.

7.6.3 Storage and Transportation

1) The DAU-7050 is ESD sensitive and standard ESD handling precautions must be observed.

The units must be placed in an anti-static bag inside a padded box. The box must be stored in a dry area
(<50%RH) where the temperature does not exceed –67°F to +185°F (–55°C and +85 °C).

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Figure 14: SRU-7200

8 SRU-7200 SATCOM REFERENCE UNIT INSTALLATION

8.1 SRU-7200 Description

1) The SRU-7200 Satcom Reference Unit (SRU) is a multi-sensor unit, providing the Satcom
system with IRS-quality aircraft attitude, heading, position and velocity information, required for
beam steering. The SRU-7200 uses its internal sensors to compute aircraft attitude and heading.

2) The SRU-7200 receives GPS position and velocity from the BSU-7100 Beam Steering Unit via a
RS 422 interface.

3) The SRU-7200 must be mounted in a magnetically clean environment when using its internal
magnetometer as a heading source. If the SRU-7200 cannot be mounted in a magnetically clean
environment, the MSU-7250 Magnetic Sensor Unit must also be installed and the SRU-7200
internal magnetic sensor deselected and not used.

4) The SRU-7200 is supplied with integral vibration isolating mounts that must be retained for
correct operation.

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8.2 SRU-7200 Satcom Reference Unit Equipment Required

PART NAME PART NUMBER QUANTITY

SRU-7200 Satcom Reference Unit 677-A0132 1
SRU-7200 Connector Kit MS3126F20-41S or 1
MS3476L20-41S or
MS3476W20-41S

Table 13: SRU-7200 Equipment Required

8.3 SRU-7200 Technical Specifications

1) Dimensions: 6.69” L x 6.38” W x 1.89” H (170mm x 162mm x 48mm)

2) Weight: 2.9 lbs (1.3 kg) maximum

3) Temperature Range: -40° F to +158° F (-40°C to +70°C) (operating)

4) Altitude: Up to 55,000 feet

5) Qualification: Environment RTCA/DO-160D,

[C4]XBBB[U(F,F1)R(C,C1)S(L,M)]EWFXFXZ[B,A]AAC[TT]H[A3E3]XAA

6) Qualification: Software RTCA/DO-178B, Level E

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8.4 SRU-7200 Installation Guidelines

8.4.1 Location Requirements

1) The SRU-7200 must be mounted within the fuselage of the aircraft. Although the SRU-7200 is
designed to function according to specification when installed anywhere in the aircraft’s fuselage,
care must still be taken in avoiding positions where the unit will be exposed to excess shocks and
vibration.

2) The SRU-7200 should not be positioned adjacent to any ferrous materials or magnetic objects. A
spacing of 39 inches (1m) from magnetic hardware is generally adequate. Note that the application of
power to electrical and avionics equipment can generate adverse magnetic fields.

3) Before the SRU-7200 is fixed in the selected location, the environmental magnetic field must be
tested. The SRU-7200 should be temporarily held in the position that is being considered as a
possible permanent location for the device. Connect the SRU to the PC using the wiring loom and run
the Installation Support Software Tool software. Select “Monitor Magnetic Field Measurements”
function and follow the on-screen instructions. While monitoring the magnetic field measurements on
the graphical display, cycle power to aircraft equipment that could affect the SRU-7200. Check for
the influence of equipment with cabling passes within 20 inches (500 mm) of the SRU. If they have
no significant effect on the magnetic field measurements (< 200 nT), the SRU-7200 can be fixed in
that position. If large variations occur in the magnetic field measurements, a new location for the
SRU-7200 must be found.

4) Note that an MSU-7250 can also be used to test for suitable locations for the SRU.

5) If the SRU-7200 cannot be mounted in a magnetically clean environment, the MSU-7250 Magnetic
Sensor Unit must also be installed and used as the heading source for the SRU (see Section 8.5.3
Configuration Strap Settings.)

8.4.2 Alignment Requirements

1) The alignment of the SRU relative to the aircraft is critical.

2) The SRU may be positioned with the connector facing fore or aft, either vertically or horizontally. It
may NOT be placed vertically with the connectors facing directly up or directly down, as water
droplets might then run into the drainage holes.

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Figure 15: Recommended SRU-7200 mounting orientations

3) The SRU must be accurately orientated either parallel or orthogonal to the main longitudinal axis of
the aircraft. This positioning must be such that the reference side of the SRU will be aligned to within
0.25° to the aircraft’s centreline.

4) It is preferred to have the SRU-7200 mounted flat, which places the least amount of stress on the
rubber mountings and eliminates any possible deformation of the mountings. By doing so, it then
implies that the SRU-7200 x or y-axis must be aligned parallel with the aircraft’s longitudinal axis.

5) This orientation option must be entered into the Installation Support Software Tool. Appendix C
contains details and examples of SRU orientations.

6) The orientation of the SRU to the aircraft in the other directions does not have to be parallel or
orthogonal to the aircraft axes. The installation software will determine these angles by making use
of the accelerometers in the SRU.

7) The roll and pitch attitude angles of the aircraft on the ground must however be determined. These
can be measured using a surface protractor (inclinometer) or by reading from the aircrafts ADI
instrument.

8) A Ø0.12 inch (3mm) alignment hole and a 0.12-inch (3mm) slot are provided to assist with
alignment, see installation drawing doc no. 677-A0132_ID for locating dimensions.

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8.4.3 Mounting Requirements

8.4.3.1 Mounting Structure

1) Mount the SRU-7200 to a rigid structure.

2) It is essential that the SRU-7200 be mounted using non-magnetic mounting hardware, when using its
internal magnetometer as a heading source.

8.4.3.2 Mounting Fasteners

1) It is recommended that four #8-32 UNC anodized aluminum alloy screws and nuts be used to fasten
this unit onto the aircraft. Suitable screws are #8-32 UNC anodized aluminum alloy screws,
MS270390008XX.

a) All assembly tools must be degaussed to remove any inherent magnetism.

b) Care must be taken not to block any of the drainage holes.

8.5 SRU-7200 Electrical interface

1) Power: 28 VDC @ 900mA

2) Minimum operating voltage: 9 VDC

8.5.1 Electrical Installation Guidelines

1) The SRU-7200 interfaces to the BSU-7100 via a RS 422 interface.

2) Keep the interconnect cables away from circuits carrying heavy current, pulse transmitting equipment
and any other potential source of interference.

3) Use shielded twisted-pair wiring for all balanced connections (RS422 and ARINC 429). Connect
shield (signal) grounds to the chassis pins provided in the connectors.

4) When designing the wire harness, keep the power grounds separate from the signal grounds and
connect them to the appropriate provided aircraft grounding points.

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8.5.1.1 SRU-7200 Maintenance Port Connectors

1) The SRU-7200 provides a RS232 maintenance port, which is made available via pins on the unit’s
multi-pin connector. This RS232 maintenance port must be terminated into a female DB9 connector
to provide the required connection to a PC 9-pin serial port.

2) The female DB9 connector should be located in an easily accessible area to facilitate installation set-
up and trouble-shooting.

8.5.1.2 Maximum Power Cable Resistance between SRU and Aircraft Power Source

1) The maximum current drawn (inrush current included) from the aircraft power source is 900mA.

2) The minimum operation voltage at which switch-off occurs is 9 Volts.

3) The combined power-line and ground return series resistance must therefore be chosen to prevent the
voltage at connector (J1) to fall below the SRU switch-off voltage.

8.5.1.3 Maximum Cable Distance between SRU and BSU

1) The maximum RS 422 cable distance is 3,900 ft. (1200 m). Refer to the wire gauge guideline in
paragraph 4.2.1).

8.5.1.4 Maximum Cable Distance between SRU and MSU

1) The power lines series resistance is important. The maximum current drawn (inrush current included)
from the SRU power source is 900mA. The minimum operation voltage at which switch-off occurs is
9 Volts.

2) The combined power-line and ground return series resistance must therefore be chosen to prevent the
voltage at connector (J1) from falling below the SRU switch-off voltage.

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8.5.1.5 Grounding Requirements

1) There is a tapped grounding point provided on the SRU base plate. Use #10-32 UNF anodized
aluminum alloy screw, MS27039001-XX, to attach grounding cable. See Figure 16.

2) Connect this to aircraft ground with a resistance ≤ 2.5 mΩ.

10 – 32 UNF Tapped Grounding Hole

Figure 16: SRU-7200 grounding point

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8.5.2 SRU-7200 (J1) Multi-pin connector:

Specification Number: MS3112E20-41P

Shell Style: Square Flange Receptacle (02)
Service Class: E
Shell Size: 20
Insert Arrangement: 41
Contact Configuration: P (Male)
Contact Type: Straight spills (PCB mounting) diameter 0.76mm
Insert Rotation: Normal (no rotation)
Materials / Finish: MIL-C-26482 Series 1
Suggested Mating Connector: MS3126F20-41S or
MS3476L20-41S or
MS3476W20-41S

Table 14: SRU-7200 (J1) Multi-pin Connector Specifications

8.5.3 SRU-7200 (J1) Connector Pin-outs:

PIN SIGNAL DESCRIPTION: COMMENT

A GPS time mark Input A GPS time mark input from BSU
B Chassis
C +28V DC Input
D +28V DC Ground Return
E MSU +28V DC Ground Return
F MSU +28V DC Output
G RS232 Rx Input Maintenance RS232 port PC connector Pin 3
H RS232 Tx Output Maintenance RS232 port PC connector Pin 2
J ARINC429 Tx Output A IRS data, connect to SDU
K ARINC429 Tx Output B IRS data, connect to SDU
L Configuration Input #1
M RS422 Tx 2 Output A
N RS422 Tx 2 Output B
P RS422 Rx 2 Input B
R RS422 Rx 2 Input A
S RS422 Tx 1 Output A Data from SRU to BSU
T RS422 Tx 1 Output B Data from SRU to BSU
U RS422 Rx 1 Input B Data from BSU to SRU
V RS422 Rx 1 Input A Data from BSU to SRU
W GPS time mark Input B GPS time mark input from BSU
X Future spare

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Y Chassis
Z ARINC429 Rx 2 Input B
a ARINC429 Rx 2 Input A
b ARINC429 Rx 1 Input B
c ARINC429 Rx 1 Input A
d Future spare
e Configuration Input #2
f Configuration Input #3
g Configuration Input #4
h Configuration Input #6
i Configuration Input #7
j Configuration Input #8
k Chassis
m Chassis
n Chassis
p Chassis
q Future spare
r Configuration Input #5
s Future spare
t Chassis

Table 15: SRU-7200 (J1) Connector pin-outs

8.5.4 SRU-7200 Configuration Strap Settings

1) The SRU-7200 uses straps for configuration purposes. Straps are either left open or connected to
ground via the chassis pins on the connectors.

Configuration
Description Unconnected Connected to ground
Input #
ARINC 429 Rx bit rate
1 (controls both receivers - for 100 kbits/s 12 kbits/s
reference SRU and ARINC GPS)
ARINC 429 Tx bit rate
2 100 kbits/s 12 kbits/s
(SDU)
3 External magnetometer Present Not present
Coded (see paragraph Coded (see paragraph
4 GPS Data Source
8.5.4.1 below) 8.5.4.1 below)
Coded (see paragraph Coded (see paragraph
5 GPS Data Source
8.5.4.1 below) 8.5.4.1 below)
6 GPS Time Mark Present Not present
Unused. Pins can be left
7 Not applicable Not applicable
unconnected
Must be configured so that number of pins
8 Parity bit
connected to ground is odd

Table 16: SRU-7200 Configuration Strap Settings

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8.5.4.1 GPS Data Source Coding for Pin 4 and 5

The GPS data source is coded as follows:

No GPS Pin 4 unconnected

Pin 5 unconnected
BSU GPS present Pin 4 connected
Pin 5 unconnected
ARINC 743 GPS present Pin 4 unconnected
Pin 5 connected
Reserved for future use Pin 4 connected
Pin 5 connected

Table 17: GPS data source pin coding

8.5.4.2 LED Definitions

Three externally visible LEDs are provided, with the following functions.

LED1 LED2 LED3

Colour Green Green Red
To indicate the
To indicate the CPU To indicate the SRU’s
Purpose availability of +28VDC
software state BITE status
input power
Label POWER CPU BITE
LED STATE
ON +28V DC available Initially 2 second LED Initially 2 second LED
test at start-up. test at start-up.
Afterwards if LED is Afterwards if LED is still
still ON, DSP in FINE ON, Low level BITE
OPERATION state failure (e.g. power
indicating valid GPS supply) or DSP not
data running
Flashing fast Unused DSP in
(5 Hz) INITIALISING or
High-level critical BITE
COARSE
failure.
OPERATION states,
(e.g. software error)
indicating lack of
valid GPS data
Flashing slow Unused DSP in SW
(0.5 Hz) DOWNLOAD state –
Unused
boot-loader firmware
running
OFF +28V DC off DSP software not
BITE OK
running

Table 18: Externally Visible LED’s

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8.6 SRU-7200 Software Set-up and Initial Checkout

1) Connect a serial port of a PC to the SRU maintenance port.

2) Run the Installation Support Software Tool and follow the on-screen instructions.

3) The Installation Support Software Tool will perform initial checkout and generate a report.

4) For the calibration procedure that must be performed after mounting the SRU-7200 the aircraft must
be completely stationary. During this process this SRU-7200 is artificially leveled.

5) The SRU-7200 algorithms require the forward/aft, port/starboard and above/below distances between
the GPS antenna and the SRU. Similarly the distances between the HGA-7000 and the SRU-7200 and
the orientation of the HGA-7000 must be entered into the Installation Support Software Tool.

6) The alignment and calibration data will be calculated by the Installation Support Software Tool and
stored in EEPROM on the SRU, along with the time and date of the installation and the aircrafts
ICAO number.

7) After the complete HGA-7000 system has been installed, a calibration procedure must be performed.
This calibration procedure is the compass swing and misalignment correction as described later in this
document. The Installation Support Software Tool will guide the installer through the procedure.

8) After the compass swing and misalignment correction has been performed, and at any time thereafter
that the systems performance appears to be inadequate, a full diagnostic check of the entire system
should be performed. This is done using the same Installation Support Software Tool that is used for
the installation and calibration procedures. Select the diagnostic tests option.

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8.7 SRU-7200 Repair and Servicing

8.7.1 Built-In Tests (BITE)

1) Faulty units are identified via the various levels of internal BITE that provide alarms and error codes.
Access to these messages is via the RS 232 interface of the BSU and the SRU. In addition, some error
messages may be accessed through the Satcom system, depending upon the system to which the
HGA-7000 system is connected.

2) Faulty SRU-7200 units must be returned to Chelton for repair.

8.7.2 Warranty Seal

1) Warranty will be void if the "Warranty Seal" on any unit is removed or damaged.

8.7.3 Storage and Transportation

1) The SRU-7200 is ESD sensitive and standard ESD handling precautions must be observed.

2) The units must be placed in an anti-static bag inside a padded box. The box must be stored in a dry
area (<50%RH) where the temperature does not exceed –40°F to +185°F (–40°C and +85 °C).

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MULTIPIN GROUNDING
CONNECTOR SCREW

ISOLATION
MOUNTS

Figure 17: MSU-7250

9 MSU-7250 MAGNETIC SENSOR UNIT INSTALLATION

9.1 MSU-7250 Description

1) The MSU-7250 Magnetic Sensor Unit (MSU) is a magnetometer which provides magnetic heading to
the SRU or BSU via a RS 422 serial interface. It must be mounted in a magnetically clean
environment for proper set-up and operation.

2) Installation of the MSU-7250 is intended for cases where the SRU-7200 (which also has a magnetic
sensor) cannot be mounted in a magnetically clean environment. It provides additional magnetic
measurements to the SRU.

3) The MSU is powered from the SRU.

4) The MSU-7250 is a sealed unit, and is supplied with integral vibration isolating mounts that must be
retained for correct performance.

9.2 MSU-7250 Magnetic Sensor Unit Equipment Required

PART NAME PART NUMBER QUANTITY

MSU-7250 Magnetic Sensor Unit 677-A0144 1
MSU-7250 Connector Kit MS3120F12-10S or 1
MS3470L12-10S or
MS3470W12-10S

Table 19: MSU-7250 Equipment Required

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9.3 MSU-7250 Technical Specifications

1) Dimensions: 6.65”L x 3.82” W x .95” H (169mm x 97mm x 24.1mm)

2) Weight: 0.926lb (0.420kg) maximum

3) Temperature Range: -67°F to +158°F (-55°C to +70° C) (operating),

4) Altitude Up to 70,000 feet

5) Qualification: Environmental RTCA/DO-160D,

[E1]XABB[U(F,F1)R(C,C1,E,E1)S(L,M,T)]EWFDFSZXXAC[TT]H[A3E3]XAA

6) Qualification: Software RTCA/DO-178B, Level E

9.4 MSU-7250 Installation Guidelines

9.4.1 Location Requirements

1) The MSU-7250 requires a magnetically clean environment. Refer to the Location Requirements,
Paragraph 8.4.1 in this document for guidelines on choosing a suitable location.

2) The MSU-7250 can be mounted in the fuselage, tail or wing.

9.4.2 Alignment Requirements

1) The MSU-7250 can be mounted at any attitude, but one of its reference axes needs to be aligned
within 0.25° of the aircraft’s longitudinal axis. The alignment of the MSU-7250 is handled in the
same way as the SRU. Refer to the appropriate sections of Chapter 8 on the SRU for more details.

2) The MSU-7250 is a sealed unit and it does not have drainage holes. Hence, unlike the SRU-7200,
there are no restrictions on orientation introduced by drainage considerations.

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9.4.3 Mounting Requirements

9.4.3.1 Mounting Structure

1) Mount the MSU to a rigid structure that will alleviate potential vibration errors induced from normal
airframe vibration. The DO-160D vibration envelopes for this unit are not to be exceeded.

9.4.3.2 Mounting Fasteners

1) It is recommended this unit be fastened onto the aircraft using four #8-32 UNC anodized aluminum
alloy screws and nuts. Suitable screws are #8-32 UNC anodized aluminum alloy screws,
MS270390008XX.

2) If stainless steel fasteners are used, then both these fasteners and all assembly tools must be
degaussed to remove any inherent magnetism.

3) See installation drawing Doc No. 677-A0144_ID for locating dimensions.

9.5 MSU-7250 Electrical interface

1) Power: 28 VDC @ 100mA

2) Minimum operating voltage: 18VDC

9.5.1 Electrical Installation Guidelines:

9.5.1.1 Maximum Cable Distance between MSU and SRU

1) The maximum RS 422 cable distance is 3900 ft. (1200 m). Refer to the wire gauge guideline in
paragraph 4.2.1).

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9.5.1.2 Grounding Requirements

1) There is a grounding point provided on the MSU base plate. This grounding point is supplied with an
M4 screw fitted at the factory. Connect this grounding point to the aircraft ground with a resistance
≤ 2.5 mΩ, using non-magnetic hardware.

2) The shield covering the pigtail cable is not connected to the MSU chassis. It is connected to Pin E on
the pigtail connector. Ensure that the shield covering the cable running from the SRU to the MSU, is
connected to the MSU mating connector Pin E.

M4 screw for grounding

Figure 18: MSU-7250 grounding point

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9.5.2 MSU-7250 Pigtail connector (J1):

Specification Number: MS3126F12-10P

Shell Style: Plug with straight cable clamp (06)
Service Class: F
Shell Size: 12
Insert Arrangement: 10
Contact Configuration: P (Male)
Contact Type: Crimp: contact size 20
Insert Rotation: Normal (no rotation)
Materials / Finish: MIL-C-26482 Series 1
Suggested Mating Connector: MS3120F12-10S or
MS34070L12-10S or
MS3470W12-10S

Table 20: MSU-7250 (J1) Pigtail connector

9.5.3 MSU-7250 Connector Pin-outs:

PIN SIGNAL DESCRIPTION: COMMENT

A MSU +28V DC input
B MSU +28V DC ground return
C RS422 Tx output A Data from MSU to SRU
D RS422 Tx output B Data from MSU to SRU
E Chassis
F RS422 Rx input A Data from SRU to MSU
G RS422 Rx input B Data from SRU to MSU
H RS232 Tx output Maintenance port data
J RS232 Rx input Maintenance port data
K Signal ground

Table 21: MSU-7250 Connector pin-outs

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9.5.4 MSU-7250 Software Set-up and Initial Checkout

1) Run the Installation Support Software Tool and follow the on-screen instructions.

2) The Installation Support Software Tool will perform initial checkout and generate a report.

9.6 MSU-7250 Repair and Servicing

9.6.1 BITE

1) Faulty units are identified via the various levels of internal Built-In Tests (BITE) that provide alarms
and error codes. The accessing of these messages is via the RS 232 interface of the BSU and/or the
SRU. In addition, some error messages may be accessed through the Satcom system, depending upon
the system to which the HGA-7000 system is connected.

2) Faulty MSU-7250 units must be returned to Chelton for repair.

9.6.2 Warranty Seal

1) Warranty will be void if the "Warranty Seal" on any unit is removed or damaged.

9.6.3 Storage and Transportation

1) The MSU-7200 is ESD sensitive and standard ESD handling precautions must be observed.

2) The units must be placed in an anti-static bag inside a padded box. The box must be stored in a dry
area (< 50%RH) where the temperature does not exceed –67°F and +185 °F (–55°C to +85°C).

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10 COMPASS CALIBRATION PROCEDURE

1) The compass calibration is applicable to system configurations that include a SRU-7200 or a SRU-
7200 with MSU-7250 combination.

10.1 Soft and hard iron calibration

1) Select “Compass Swing Calibration” as prompted by the Installation Support Software Tool.

2) Taxi the aircraft in a circle at a rate of less than six degrees per second, as smoothly as possible.

3) When the circle is complete, continue to taxi in a circle in the opposite direction. This is shown in
Figure 19, with the aircraft stopping in the same position and orientation as where it started.

4) The software will provide prompts to allow the installer to indicate the start and completion of the
compass swing.

5) The Installation Support Tool will process the data and indicate if the calibration was successful or
not based on the match between the measured and theoretical magnetic fields in horizontal and
vertical directions.

Figure 19: Aircraft compass swing

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10.2 Misalignment correction

10.2.1 Procedure

1) The misalignment is determined by comparing the magnetic heading with an external reference, e.g. a
“landing” compass.

2) The procedure is to point the aircraft to within 5 degrees of each of the four cardinal headings. At
each heading the aircraft magnetic heading needs to be measured with the accurate external reference
and entered into the Installation Support Software Tool.

3) The software will calculate the alignment error at each of the four cardinal headings. The average of
the four heading errors will be used as the misalignment correction.

10.2.2 Analysis of failed calibrations

1) If the alignment errors are all large and of the same sign (all values positive or all values negative)
then this indicates that the SRU-7200 or MSU-7250 was not properly aligned with the longitudinal
axis of the aircraft.

2) If this occurs then the alignment of the MSU-7250 (if one is fitted) or the SRU-7200 (where there is
no MSU-7250) must be repeated. Refer to Chapters 9.4 and 8.4 respectively in this document and
repeat the alignment procedure.

3) Alignment errors with a mixture of large positive values and large negative values indicate either that
the calibration process was incorrectly executed or that the magnetic environment of the devices is
unsuitable.

4) If this occurs then repeat the compass swing procedure. If the result is the same, the magnetic field
environment in the area of the magnetometer is unsuitable and a better mounting position must be
found.

5) For an installation that includes an SRU-7200 without MSU-7250, the SRU-7200 must be relocated
or an MSU-7250 can be added to the installation. For an installation that already has an MSU-7250,
the MSU needs to be repositioned.

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10.3 Repeating a compass swing

1) Normal aircraft practices apply in terms of checking the accuracy of the compass and re-calibrating
the compass. Based on Advisory Circular 43.13-1B, Chapter 12 the calibration procedure should be
repeated:

ƒ When the accuracy of the compass is suspect

ƒ Whenever the compass has been subject to shock; for example after a hard landing or shock

ƒ After the aircraft has passed through an electrical storm

ƒ After a lightning strike

ƒ Whenever a change is made to the electrical system

ƒ Whenever a change of cargo is likely to affect the compass

ƒ When an aircraft operation is changed to a different geographic location with a major change
in magnetic deviation

ƒ After the aircraft has been parked on one heading for over a year

ƒ When the magnetometer is replaced. This refers to the SRU-7200 if there is no MSU-7250 in
the installation

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11 DIAGNOSTICS AND FAULTFINDING

1) An extensive system of testing is built into the HGA-7000 system.

2) The same PC program (Installation Support Software Tool) that is used for installation can be used
for testing the HGA-7000 system at any time. The tests must be performed at least once at the end of
the initial installation.

3) To execute the tests, connect a serial extension cable from the serial port of the PC to the maintenance
port of the BSU, run the Installation Support Software Tool and follow the instructions on the screen.

4) All of the modules in the HGA-7000 system have built-in testing capabilities. The units test
themselves for both non-critical warnings and fatal errors whenever they are used. Details of these
faults are recorded in non-volatile memory and may be extracted at any time, even long after the fault
has occurred.

5) The BSU can act as a transparent conduit between a maintenance PC and any of the other peripherals
(HGA, SRU, MSU, and DLNA), allowing detailed live performance testing and monitoring of any of
the devices.

6) The PC software produces log files that can be sent back to Chelton for analysis.

7) All of the calibration and alignment procedures can also be repeated at any time. Refer to the
installation sections of this document and follow the directions given by the Installation Support
Software Tool.

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Appendix A: Drawings

Important: Whenever a BSU-7100 or SRU-7200 is installed; it is mandatory to wire the maintenance

ports (shown below as PC COM 1 for BSU-7100 and PC COM 2 for SRU-7200). These connectors must
be easily accessible to the Installers.

Figure 20: Suggested HGA-7000 System interconnect wiring diagram for minimum installation (option
strapping excluded, see Table 7)

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Figure 21: Suggested HGA-7000 System interconnect wiring diagram for installation with SRU and
MSU included (option strapping excluded, see Table 7 and Table 16).

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Figure 22: Suggested HGA-7000 System interconnect wiring diagram for installation with TT HSD++
using SRU with MSU (option strapping excluded, see Table 7 and Table 16).

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Appendix B: Chelton Installation Kit, 780-A0465

Detailed information regarding the use of this kit can be found in Reference 0.

PART NAME PART NUMBER QUANTITY

Comprises
o Mounting Plate 478-A1423 1
o Nut Plate Ø5 478-A1927 8
o Nut Plate Ø4 478-A1938 8
o HGA-7000 Installation Template 478-A1879 1

Table 22: Chelton Installation Kit

1) After the best position on the fuselage has been determined from RF considerations the exact position
must be determined whilst bearing in mind all the holes and structural additions that must be made.
The installation must accommodate the increased loads on the airframe as well as adapt the flat
underside of the antenna to the curvature of the fuselage.

2) Each airframe type has a different radius and this radius must be supplied to Chelton when placing a
purchase order so that the correct plate shape can be supplied.

3) The mounting plate comes with clearance holes that match the mounting holes of the antenna as the
antenna is fixed to the aircraft and the mounting plate does not carry any structural load.

4) The antenna can be removed from the aircraft with out removing the mounting plate.

5) A cross section of a typical installation is shown below. Note that the mounting plate is fixed to the
fuselage independently from the antenna and that the fuselage mounting hole positions are not
defined, it is left to the installer to determine the optimum position of the holes to accommodate
structural members on the inside of the aircraft fuselage.

6) The mounting plate is machined from 6082 T6 Aluminum.

7) The mounting plate has drain channels on its underside to prevent the build up of water between the
antenna base and the fuselage.

8) In order to prevent the possibility of corrosion between the mounting plate and the aircraft skin, it is
recommended that a suitable flexible sealant such as PRC PR-1440 Fuel Tank Sealant (not supplied)
be applied between the plate and the fuselage only. Care must be taken to avoid blocking the drain
channels in the mounting plate.

9) The mounting plate must be grounded to the fuselage with a resistance of ≤ 2.5mΩ. Various alternate
methods of grounding are shown in Figure 23.

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Grounding via Direct grounding of

Mounting Plate Antenna

Direct grounding of
Mounting Plate

Grounded anchor
nut and Nut Plate

Seal over Grounded anchor

Grounding of Mounting
ground strap nut and Nut Plate
Plate to the inside using
ground strap
Bend and drill
ground strap to suit

Grounding of Mounting
Bend and drill Plate to the outside using
ground strap to suit ground strap
Seal over
ground strap

Figure 23: Cross section of various grounding methods

Figure 24: HGA-7000 Mounting Plate

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Sealing Kit (Cap, Foam Plug

and O-ring) supplied. Apply
Si RTV to thread

#10-32 bolt for mounting (8

places)

Do not apply sealant. O ring

in antenna base provides the
seal
Seal interface between HGA and
Mounting Plate with bead of flexible
sealer in recess
Seal and fair interface between Mounting
Plate and airframe with fillet of flexible
sealer (Leave drainage channels open)

Mounting Plate
Fix Mounting Plate to fuselage (holes not
External doubler plate
supplied in plate)
(wet installed)
Apply sealant at all contact
areas between Mounting Sealed anchor nut
Plate and fuselage to
prevent fretting and Fix center portion of
moisture entrapment Mounting Plate

Figure 25: Installation Cross-Sections

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Appendix C: SRU and MSU Reference Axis

1) The basic requirement for the alignment of the SRU and MSU is that one of the unit’s principal axes
needs to be aligned with the aircraft’s longitudinal axis. The selected axis aligned with the aircraft’s
longitudinal axis needs to be indicated in the Installation Support Software Tool as well as the
direction it is pointing, i.e. towards the nose or towards the tail. The Installation Support Software
Tool will automatically determine azimuth alignment of the units with respect to the aircraft’s
longitudinal axis.

2) Once this has been indicated, the synthetic / artificial leveling can be performed during which the
installation angles are determined, i.e. the roll and pitch angles of the unit’s principal axis with respect
to that of the aircraft. To do this, the installer only needs to provide the aircraft’s roll and pitch angles
at the time of running the Installation Support Software Tool.

3) The coordinate system can be illustrated by considering a default configuration where the principal
axis of the SRU and MSU are aligned with the principal axis of the aircraft.

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X
a/c

Y
a/c
X
X
SRU
MSU
Y
SRU
Y
MSU

Figure 26: Default alignment

4) Using Figure 26 as baseline, it is now possible to illustrate some of the other possible installations.
The following illustrations are for a person looking forward in the aircraft, and not from the top as in
Figure 26.

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y y
x y
SRU a/c
SRU a/c

z z
SRU SRU

z z
a/c a/c

The SRU has been rotated 90 degrees clockwise from the

Default installation of SRU as showed in Figure 1, but
default, i.e. the y-axis of the SRU is now pointing towards the
viewed looking forward.
tail.
x y
SRU a/c y
a/c

z y
SRU SRU
z
SRU
z
a/c
z
a/c
Default installation of SRU as shown in Figure 1, but mounted at
The SRU has been rotated 90 degrees counter-clockwise
an angle. The x-axis of the SRU is still aligned with the aircraft's
from the default, i.e. the y-axis of the SRU is now pointing
longitudinal axis. The angle the SRU is mounted at will be
towards the nose.
determined during synthetic / artificial leveling.

x
SRU

y
z
a/c
SRU
y
a/c

z
a/c

The SRU has been rotated 90 degrees counter-clockwise from

The SRU has been pitched up through 90 degrees, i.e. the z-
the default, i.e. the y-axis of the SRU is now pointing towards
axis of the SRU is now pointing towards the nose. The
the nose. It has also been rolled through 90 degrees. The exact
exact pitch attitude of the SRU will be determined during
roll attitude will be determined during synthetic / artificial
the synthetic / artificial leveling of the SRU.
leveling.

Figure 27: Sample Installation Configurations

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Appendix D: Typical Installation Configurations

AERO High Gain Antenna

Lightning
Ground
Co-Axial
connection connectors Aircraft
Fuselage

Steering
Control

RF
Signals

Coax:
Modem
Data

ARINC 429
TT HSD + IRS Interfaces
OEM
Equipm ent

Aircraft
supply
Interconnection to T T HSD+ minimum configuration

Figure 28: Interconnection to TT HSD+ minimum configuration

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AERO High Gain Antenna

Lightning
Ground
Co-Axial
connection connectors Aircraft
RF Steering Fuselage
Signals Control

Optional
MSU

Maintenance
Aircraft power

Satcom
Beam Steering
Reference
Unit
Data Unit

Coax:
RF path
Modem
Data
ARINC 429
SRU IRS
TT HSD + OEM
Equipm ent

Aircraft
supply
Interconnection to T T HSD+ using SRU in autonomous configuration

Figure 29: Interconnection to TT HSD+ using SRU with MSU in autonomous configuration

Document: 862-A0043_IM COMPANY CONFIDENTIAL

Issue: 8.11
Page 91 of 93
HGA-7000 High Gain Antenna System
Installation Manual

AERO High Gain Antenna

Lightning
Ground
Co-Axial
connection connectors Aircraft
RF Steering Fuselage
Signals Control

ARINC
DLNA Optional
MSU

BITE Maintenance
Aircraft power

Satcom
Beam Steering
Reference
Unit
Data Unit

Tx path Rx path ARINC 429

BSU Interface

ARINC 429 IRS

Interface

HPA SDU OEM

Equipm ent

Aircraft
supply
Interconnection to OEM SDU using SRU in autonomous configuration

Figure 30: Interconnection to OEM SDU using SRU in autonomous configuration

Document: 862-A0043_IM COMPANY CONFIDENTIAL

Issue: 8.11
Page 92 of 93
HGA-7000 High Gain Antenna System
Installation Manual

AERO High Gain Antenna

Lightning
Ground Co-Axial
connection connectors Aircraft
RF Steering Fuselage
Signals Control

ARINC
DLNA

BITE

Aircraft power
Beam Steering
Unit
Maintenance

Tx path ARINC 429 BSU

Rx path
Interfaces

ARINC 429 IRS

Interface
HPA SDU OEM
Equipment

Aircraft
supply
Interconnection to OEM SDU using aircraft IRS

Figure 31 Interconnection to OEM SDU using aircraft IRS

Document: 862-A0043_IM COMPANY CONFIDENTIAL

Issue: 8.11
Page 93 of 93