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Satellite
Satellite Terminal
Terminal
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Maritime
Maritime Installation
Installation Guide
Guide
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3500867-0001
3500867-0001
Revision
Revision 22
November
November 27,27, 2013
2013
 Copyright © 2013 Hughes Network Systems, LLC
All rights reserved. This publication and its contents are proprietary to Hughes Network Systems,
LLC. No part of this publication may be reproduced in any form or by any means without the written
permission of Hughes Network Systems, LLC, 11717 Exploration Lane, Germantown, Maryland
20876.
Hughes Network Systems, LLC has made every effort to ensure the correctness and completeness
of the material in this document. Hughes Network Systems, LLC shall not be liable for errors
contained herein. The information in this document is subject to change without notice. Hughes
Network Systems, LLC makes no warranty of any kind with regard to this material, including, but
not limited to, the implied warranties of merchantability and fitness for a particular purpose.

Trademarks
Hughes and Hughes Network Systems are trademarks of Hughes Network Systems, LLC. All other
trademarks are the property of their respective owners.
 Contents
Understanding safety alert messages ..................................................................................... vii
Messages concerning personal injury ...................................................................................................... vii
Safety symbols .......................................................................................................................... vii
Chapter 1 Introduction .........................................................................................................9
Hughes mobile satellite terminals .............................................................................................................. 9
Below Deck Unit (BDU) ......................................................................................................................... 10
Physical dimensions ............................................................................................................................. 10
Power port ............................................................................................................................................ 11
Table 2. Power port pin out ................................................................................................................ 11
Four RJ-45 Ethernet with Power over Ethernet (PoE) ports ................................................................ 11
WLAN port .......................................................................................................................................... 12
Antenna port......................................................................................................................................... 12
SIM card............................................................................................................................................... 12
System power requirements ................................................................................................................. 13
Table 4. System power requirements ................................................................................................. 13
Fuse ...................................................................................................................................................... 13
Chapter 2 Below Deck Unit (BDU) Install ........................................................................15
Basic BDU installation procedure............................................................................................................ 15
Installation notes ...................................................................................................................................... 15
BDU mounting information ..................................................................................................................... 16
Chapter 3 Above Deck Unit (ADU) Install .......................................................................17
Physical dimensions ................................................................................................................................. 17
Antenna cable lengths and types .............................................................................................................. 17
Antenna Location ..................................................................................................................................... 18
Antenna Mounting ................................................................................................................................... 20
Antenna Vibration.................................................................................................................................... 22

x Contents LLL
Revision A
 Figures
Figure 1-1. BDU (left) and ADU (right) Maritime antenna..................................................................... 9
Figure 1-2. Below Decks Unit (BDU) ................................................................................................... 10
Figure 1-3. Fitting the SIM card Cover.................................................................................................. 12
Figure 2-1. BDU - mounting dimensions in mm. .................................................................................. 16
Figure 2-2 BDU Wiring Diagram ......................................................................................................... 16
Figure 3-1. ADU - Maritime Antenna ................................................................................................... 17

Tables
Table 1. Maritime Kit Parts ................................................................................................................... 10
Table 2. Power port pin out.................................................................................................................... 11
Table 3. RJ-45 Ethernet port pinout ....................................................................................................... 11
Table 4. System power requirements ..................................................................................................... 13

x Figures Y
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Understanding safety alert messages
Safety alert messages call attention to potential safety hazards and tell you how to
avoid them. These messages are identified by the signal words WARNING or
CAUTION, as illustrated below. To avoid possible property damage, personal injury, or
in some cases possible death, read and comply with all safety alert messages.

Messages concerning
personal injury
The signal words WARNING and CAUTION indicate hazards that could result in
personal injury or in some cases death, as explained below. Each of these signal
words indicates the severity of the potential hazard.

WARNING indicates a potentially hazardous situation,

which if not avoided, could result in death or serious
injury.

CAUTION indicates a potentially hazardous situation,

which if not avoided, could result in minor or moderate
injury.

Safety symbols

The generic safety alert symbol calls attention to a potential personal injury
hazard. It appears next to the WARNING and CAUTION signal words as part of the
signal word label. Other symbols may appear next to WARNING or CAUTION to
indicate a specific type of hazard (for example, fire or electric shock).

x Safety YLL
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Chapter 1 Introduction
The purpose of this guide is to provide assistance to personnel installing the Thuraya
Orion IP mobile satellite terminal into a Maritime vessel.

This terminal must be installed by Authorized Service

Personnel.
Note: Damages resulting in the failure to conform to the
instructions found herein, as well as standard installation
practices, will be the responsibility of the installer.

Hughes mobile satellite terminals

The mobile satellite terminals are composed of four core component parts: the
transceiver or Below Deck Unit (BDU), the antenna or Above Deck Unit (ADU), the
power connector/cable, and a 25 meter RF cable.

Figure 1-1. BDU (left) and ADU (right) Maritime antenna

x Package materials 
Revision 1
 The Thuraya Mobility (Maritime) kit is shipped with the following contents:
Model Hughes part Description
number
Thuraya Orion IP (9105) 3500462-0004 Radio, Thuraya Orion IP (kit)
Maritime kit
9506197-0001 WLAN antenna (2.4 GHz, 3 dB)

3500472-0003 Power cable with 3-pin connector

3500860-0001 SIM cover plate

9504275-0008 15 Amp, fast blow, ATO blade fuse (2 pieces)

PDF Install Manual

PDF User Manual

3500854-0001 Maritime Antenna Type HN321

TNC-N/25m RF coax cable TNC-N (25 meter)

Table 1. Maritime Kit Parts

Below Deck Unit (BDU)

The BDU provides all of the TE interfaces, plus the interface for the antenna (ADU)
and manages the communications over the Thuraya network. Communication to the
ADU is provided by a single RF cable from the BDU.

Physical dimensions
BDU: Size: 46mm x 281mm x 233mm
Weight: 2.2kg

Figure 1-2. Below Decks Unit (BDU)

 x Package materials

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Power port
The power port is the connection from the power supply (vessel battery or some other
12 or 24Vdc power source) to the BDU. The power cable has a DC positive power line,
a Remote Switch line and a DC negative power line.

Line type Pin number

V+ DC power line 1
Remote Switch 2
V- DC power line 3

Table 2. Power port pin out

Four RJ-45 Ethernet with Power over Ethernet (PoE) ports

There are four RJ-45 ports with Power over Ethernet (PoE) on the BDU. The ports
supply standard PoE according to the IEEE 802.3af standard and 10/100BaseT
Ethernet. The pinout of the ports supports a direct straight-through connection to a PC
with a standard Ethernet cable. Table 3 shows the pinout of the Ethernet connector.
Pin
1 RX+
2 RX-
3 TX+
4 NC
5 NC
6 TX-
7 NC
8 NC

Table 3. RJ-45 Ethernet port pinout

Note: The +48V and -48V are supplied over the TX, RX pairs.
They are only active when an 802.3af compliant device is
plugged in. The other pairs (4, 5, 7, and 8) are unused.
All four Ethernet interfaces support up to 15 Watts of power to each PoE powered
device. The total power supplied by the PoE is limited to 30W maximum for 12 V
installations. The BDU automatically detects the class of the device plugged in and will
apply power so that the total cannot exceed these limits. If the user attempts to
connect a combination of devices that require more than this, the BDU will not power
any devices that would cause the limit to be exceeded.
Note: Class 4 (802.3at) PD devices are not supported.

x Package materials 

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WLAN port
The WLAN port on the BDU is a reverse polarity SMA jack. A flexible antenna with
RP-SMA plug connector is supplied, part number HG2403RD-RSF.
To prevent blocking or attenuation of the WLAN signal, the BDU should be installed
such that there is no metal blocking the radio path to the user’s device.

Antenna port
The ADU (antenna) connects to the 50 Ohm female TNC connector antenna port on the
BDU by an RF cable which carries L-band RF; signaling, & DC power (42Vdc) for the
antenna.
NOTE: The antenna cable carries DC power; do not connect or disconnect the antenna
cable while the unit is powered on.

ONLY use the Thuraya Maritime Antenna Type HN321 with this BDU – use of other
antennas may damage the BDU and Antenna and shall void the warranty.

SIM card
SIM Card: The BDU requires a Thuraya SIM to be installed. Insert the SIM (supplied
by your service provider) into the SIM card holder with the metal contacts facing down.
A SIM card cover is supplied as an accessory with the BDU and may be utilized if
desired. Use this to prevent accidental removal of the SIM card or if additional security
is required. Note: the following tool (not supplied) is required to fit the SIM Card
Cover: Screwdriver, Torx 8 (for a metric M2.5 screw). See Figure 1-3 for attaching the
SIM card cover.

Figure 1-3. Fitting the SIM card Cover

 x Package materials

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System power requirements
There is one power connection on the BDU. This must be connected to a 12 or 24Vdc
supply. Power requirements and consumption are as follows:

Voltage Input Minimum 10V

Voltage Input Maximum 32V
Total Current for ADU and BDU 12A
(Max. @12V)
Required Fuse 15A

Table 4. System power requirements

Fuse
The fuse is a 15 Amp, fast blow, ATO blade fuse. The installed part is from Littelfuse,
part number 0257015. To replace the fuse, pull fuse out of fuse holder (pliers may be
needed to grip fuse) and press new fuse into fuse holder. Spare fuses are provided
with your Thuraya Mobility terminal.

x Package materials 

Revision 1
Chapter 2 Below Deck Unit (BDU) Install
The BDU is generally located in an area accessible by the operator and protected from
water/spray. The ADU is generally located in a position to give clear line of sight to the
satellite and to avoid exposure of microwave radiation to personnel.

Basic BDU installation

procedure
The basic installation procedure is as follows:
1. Ensure that the BDU is located inside the vessel in a position that is protected
from salt water/spray/heat and attached to something structurally solid. Locations
that vibrate will degrade performance. Note: The BDU is not waterproof.
2. Determine the power cable routing from the BDU to the power source.
3. Determine an RF cable routing from the BDU to the ADU. The ADU will need to
be mounted so that it has a 360o clear view of the sky and is not within one meter
of personnel on the boat (side and top surfaces).
4. Perform the installation of the BDU per the instructions below.

Installation notes

1. Use the correct gauge of wire for both Positive and Negative wires to ensure a
minimal voltage drop under load. Suggested wire size: 14 AWG: up to 8m (26ft),
12 AWG: up to 12m (40ft), 10 AWG: up to 20m (65ft).
2. The power must be connected to a fused 12 or 24Vdc power source. The unit is
fused, but a 15A or greater fuse is required in the source to protect against shorts
in the cabling. If connecting to a circuit in a DC panel that is already in use,
ensure that the circuit can supply the unit with up to 15A for a 12V installation or
7.5A for a 24V installation.
3. Use cable ties every 300 – 450mm (12"-18").
4. BDU - Ground the chassis ground bolt to a nearby vessel RF ground point with a
wire 8 AWG or larger.
5. Whenever routing cable through holes drilled in metal or through bulkheads, use
grommets and RTV sealant to weatherproof all holes drilled on the outside of the
vessel.
6. Always provision the wiring into the BDU with a drip loop.
7. With the exception of the BDU-to-antenna RF cable, do not route the power
cable outside the vessel.
8. BDU MUST NOT be mounted closer than 1.0 m (3.3 ft) to a Magnetic Compass,
Fluxgate Compass or other heading device – it is strongly recommended that any

x Below Deck Unit (BDU) 

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 nearby Compass/heading device is checked for any change in deviation after
installing the terminal.

BDU mounting information

1. The BDU can be mounted in either the horizontal or vertical position.
2. Install the BDU in a protected but ventilated area. Allow at least a 1-inch space
around top and sides to provide adequate cooling.
3. Mount the terminal onto a flat surface using at least four screws or bolts (not
supplied). Use screws or bolts with a diameter between 3.5 to 4mm. Vibration-
resistant screws or lock washers should be used.

Dimension BETWEEN Mounting Holes: 271mm

Dimension BETWEEN Mounting Holes:

182.5mm

Figure 2-1. BDU - mounting dimensions in mm.

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Figure 2-2 BDU Wiring Diagram

 x Package materials

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Chapter 3 Above Deck Unit (ADU) Install
The antenna unit (ADU) is composed of the antenna element, high-power and low-
noise amplifier systems, and a mechanical tracking system housed in the radome.
The ADU is a SpaceCom HN321 3-axis antenna intended for maritime use.
Connection to the ADU is made by an N connector. The single coaxial cable carries
L-band RX and TX, power, and control information.

Physical dimensions
x ADU: Size: 319.5mm x 277mm
Weight: 4kg

Figure 3-1. ADU - Maritime Antenna

Antenna cable lengths

and types
The Hughes BDU has an automatic cable calibration feature that determines the loss
of the cable. The RF cable that comes standard in the terminal kit is 25 meters long. If
a different cable is required for the installation, the end-to-end RF loss needs to be
10dB +0dB/-8dB at 1.6GHz and the cable must be 50 Ohm impedance.
Note: The installer is responsible for choosing the proper type of cable for the length
required in order to meet the loss requirement.

x The Antenna - Above Deck Unit (ADU) 

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 Antenna Location
It is important for the operation and life of the Antenna and safety of personnel that the
location / mounting / fitting instructions are followed – improper installation will void any
warranty.
Mounting Location:
x Line-of-Sight: when locating the antenna, it is very important to ensure
there is a clear line-of-sight to the satellite for all the satellite elevation
angles in the region in which the ship will operate. The antenna rotates
360° and down to –25° for pitch and roll to allow for continuous pointing
even in heavy sea conditions. Any obstructions within this arc can cause
some signal degradation. The amount of degradation depends on the size
of the obstruction and the distance from the antenna but in general any
obstructions within 3 meters (10 feet) of the antenna should be avoided.
Obstructions less than 150 mm (6 inches) in diameter can be ignored
beyond this distance.

x Radar: DO NOT install the antenna on the same plane as a Radar

Antenna – the High Power Radar signal can damage or overload the
antenna front-end circuits – the Antenna must be mounted above or below
the Radar beam – See following tables of recommended distances
depending on the type of Radar(s) used.

Antenna Location – minimum distance from RADAR

(S-Band)
Radar Min Distance @ 15ࡈࡈ Min Distance at 6ࡈ
Power vertical separation vertical separation
Output
0-10kW 0.4 m (1.3 ft.) 0.4 m (1.3 ft.)
30kW 1.0 m (3 ft.) 0.5 m (3 ft)
50kW 2.0 m (6.6 ft) 1.0 m (3.3 ft)

 x The Above Deck Unit (ADU)

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 Antenna Location – minimum distance from RADAR
(X-Band)
Radar Min Distance @ 15ࡈࡈ Min Distance at 6ࡈ
Power vertical separation vertical separation
Output
0-10kW 0.8 m (2.6 ft.) 0.4 m (1.3 ft.)
30kW 2.4 m (7.9 ft.) 1.2 m (3.9 ft)
50kW 2.0 m (6.6 ft) 2.0 m (6.6 ft)

NAVIGATIONA AIDS: see the table below for suggested co-location minimum
distances of other transmitting/receiving antennas;

Antenna Location – Minimum Distance from NAV-AIDS

VHF 5.0 m (16.4 ft)
MF/HF (SSB) 5.0 m (16.4 ft)
Other L-Band Transmitters 10.0 m (32.8 ft)
GPS Install below antenna beam -
10.0 m (32.8 ft) if in same plane
as antenna beam

NOTE: If there is other equipment installed near the Thuraya satellite terminal, it
is recommended to operate all equipment simultaneously and verify there is no co
interference.

Radiation: locate the antenna so that personnel are not exposed to microwave
radiation from the Antenna when transmitting - keep a minimum safe distance of 1
meter (39 inches) to the side and above the antenna.

Antenna Cable: the antenna cable carries DC power. Always power the BDU
down prior to connecting or disconnecting the antenna cable from either the ADU
(antenna) or the BDU.

x The Antenna - Above Deck Unit (ADU) 

Revision 1
 Antenna Mounting
Pedestal/Pole Mounting / Fitting Instructions:
See the figure below for the installation of the Thuraya Maritime HN321 antenna on a
pedestal. Connect the N-connector on the coax cable as shown before fastening the
antenna to the pole mount. Do not obstruct the drain holes at the bottom of the
antenna (around the N-connector) and at the bottom of the pole mount. Note: the
antenna cable carries DC power. Always power the BDU down prior to connecting or
disconnecting the antenna cable from either the antenna or the BDU.

 x The Above Deck Unit (ADU)

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Alternate Mounting Hardware:
It is recognized that for some installations Custom mounts/mounting brackets may be
required. The following template is provided for the Antenna footprint.
NOTE: the Antenna must be fitted to allow for natural water drainage – please see template
information – Failure to follow this requirement shall void any warranty.

x The Antenna - Above Deck Unit (ADU) 

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 Antenna Vibration
The antenna is designed to meet the following operational vibration levels in any of
three perpendicular directions measured at the mounting base of the radome i.e. at
the flange of the mounting pole.

Random Vibration:
1.05 grms with the following spectral density
5-20Hz………….0.02g2/Hz
20-150Hz……….-3dB/octave
Single Frequency Vibration:
5-10Hz with amplitude 2.54 mm
10-15Hz with amplitude 0.76mm
15-25Hz with amplitude 0.40mm
25-33Hz with amplitude 0.23mm

Note: Vibration levels in a typical installation are usually much less than the above
mentioned values. It is however the responsibility of the installer to verify, that the
cited levels are not exceeded in any mode of operation of the vessel. In case of
abnormal vibration, typically at a resonance frequency, measures must be taken in
order to displace the resonance frequency or to dampen the vibration amplitude.

 x The Above Deck Unit (ADU)

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