IDP-800

Hardware Guide
Version 06
Apr 2016
 IDP-800 - HARDWARE GUIDE

TABLE OF CONTENTS
List of Figures ................................................................................................................................ 6
List of Tables.................................................................................................................................. 8
Preface .......................................................................................................................................... 10
Purpose ....................................................................................................................................... 10
Audience ..................................................................................................................................... 10
Errata Sheet ................................................................................................................................. 10
Notation ...................................................................................................................................... 10
Reference .................................................................................................................................... 10
Battery Safety Warnings ............................................................................................................. 10
Product Safety Datasheets .......................................................................................................... 11
Safety Disclaimer ........................................................................................................................ 11
Safety Precautions....................................................................................................................... 11
Installation Warning ................................................................................................................... 12
Installer Responsibility ............................................................................................................... 12
Limited Liability ......................................................................................................................... 12
Warranty ..................................................................................................................................... 13
User Serviceable Parts ................................................................................................................ 13
1 Product Overview ............................................................................................................. 14
1.1 Overview of the Messaging System ................................................................................. 14
1.2 Terminals .......................................................................................................................... 15
1.3 Remote Antennas ............................................................................................................. 16
1.4 Terminal Key Features and Benefits ................................................................................ 17
1.5 Pass-Through Mode ......................................................................................................... 17
1.6 Operating Modes .............................................................................................................. 17
1.6.1 Satellite Modem........................................................................................................ 17
1.6.2 Application Controller .............................................................................................. 18
1.6.3 GPS/GLONASS ....................................................................................................... 18
1.6.4 Accelerometer Modes ............................................................................................... 18
1.6.5 Application Peripherals ............................................................................................ 18
1.6.6 Power Modes ............................................................................................................ 19
2 Compliance ........................................................................................................................ 20
3 Specifications ..................................................................................................................... 23
3.1 Temperature...................................................................................................................... 23
3.1.1 Terminal Temperature .............................................................................................. 23
3.1.2 Battery Temperature ................................................................................................. 23
3.2 Electrical........................................................................................................................... 23
3.2.1 External Voltage Input.............................................................................................. 23
3.2.2 Operational Power Consumption.............................................................................. 24
[Link] Power Consumption Scenario .............................................................................................25
[Link] GPS and GLONASS Power Consumption ..........................................................................26
[Link] Blockage Power ..................................................................................................................26
[Link] Accelerometer Power Consumption ....................................................................................27
3.2.3 Power off Controls ................................................................................................... 28
3.2.4 Power Input Options ................................................................................................. 29
3.2.5 Load Dump Circuitry................................................................................................ 30
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3.2.6 Fuse........................................................................................................................... 30
3.2.7 Inrush Current ........................................................................................................... 30
3.2.8 Reverse Voltage Input .............................................................................................. 31
3.2.9 LED .......................................................................................................................... 31
[Link] LED-Magnet Interaction .....................................................................................................32
[Link] User Control ........................................................................................................................33
3.2.10 Power Connector ...................................................................................................... 33
[Link] Connector Pin-out ...............................................................................................................33
3.2.11 Input / Output ........................................................................................................... 33
[Link] Input / Output Specifications ...............................................................................................34
[Link] Analog Accuracy .................................................................................................................35
3.3 RF Connector ................................................................................................................... 36
3.3.1 Antenna Cut Detection ............................................................................................. 36
3.4 Pass-Through Mode ......................................................................................................... 36
3.5 Serial Interfaces ................................................................................................................ 38
3.5.1 RS-232 ...................................................................................................................... 38
[Link] Auto RS-232 Power On/Off ................................................................................................38
3.6 RF Specifications ............................................................................................................. 39
3.6.1 Frequency ................................................................................................................. 39
3.6.2 IDP-800 Terminal with Integrated Antenna ............................................................. 39
3.6.3 Remote Standard Antenna ........................................................................................ 39
3.6.4 Remote Low Elevation Antenna............................................................................... 39
3.7 GPS/GLONASS ............................................................................................................... 40
3.7.1 1 PPS Signal ............................................................................................................. 40
3.8 Internal Battery ................................................................................................................. 41
3.8.1 Battery Type ............................................................................................................. 41
3.8.2 Battery Type Identification ....................................................................................... 41
3.8.3 Battery Lid Matching................................................................................................ 42
3.8.4 Battery Protection ..................................................................................................... 43
[Link] Non-Rechargeable (Li/FeS2) Cells ......................................................................................43
[Link] Rechargeable (NiMH) Cells ................................................................................................44
3.8.5 Charger ..................................................................................................................... 44
[Link] Charger Stages Initiation .....................................................................................................46
[Link] Temperature Monitoring .....................................................................................................46
3.8.6 Charging Stages ........................................................................................................ 46
3.8.7 Battery Monitoring ................................................................................................... 47
[Link] Battery Voltage ...................................................................................................................48
[Link] Long Messages ....................................................................................................................48
3.9 Accelerometer .................................................................................................................. 48
3.10 Nonvolatile Storage .......................................................................................................... 49
3.11 Environmental .................................................................................................................. 49
3.12 Mechanical ....................................................................................................................... 52
3.12.1 Terminal ................................................................................................................... 52
3.12.2 Remote Antenna ....................................................................................................... 53
4 Installation ......................................................................................................................... 55
4.1 Getting Started.................................................................................................................. 55
4.2 Prepare for the Installation ............................................................................................... 55
4.2.1 Shipping Box Contents ............................................................................................. 55
4.2.2 Mobile Identification ................................................................................................ 56
4.2.3 Activate the Terminal ............................................................................................... 56

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4.2.4 Programming the Terminal ....................................................................................... 58

4.2.5 Required Materials ................................................................................................... 58
4.2.6 Required Tools ......................................................................................................... 58
4.3 Determine a Suitable Mounting Location ........................................................................ 58
4.3.1 Review Remote Antenna Mounting Guidelines (Optional) ..................................... 59
4.4 Identify the Fuse Panel Location (optional) ..................................................................... 60
4.5 Prepare the Batteries ......................................................................................................... 61
4.5.1 Install the Batteries ................................................................................................... 61
4.5.2 Test the Battery Installation...................................................................................... 62
4.5.3 Attach the Battery Cover .......................................................................................... 65
4.5.4 Recharge the Batteries .............................................................................................. 67
4.5.5 When to Power Off the Terminal ............................................................................. 68
4.5.6 How to Power On the Terminal ................................................................................ 68
4.6 Mount the Terminal .......................................................................................................... 68
4.6.1 Determine Terminal Orientation for Accelerometer Use ......................................... 69
4.6.2 Drill Mounting Holes................................................................................................ 70
4.6.3 Custom Bracket Guidelines ...................................................................................... 70
4.7 Mount the Remote Antenna (optional) ............................................................................. 70
4.7.1 Screw Mount ............................................................................................................ 70
4.7.2 Adhesive Mount ....................................................................................................... 72
[Link] Silicone Side Connector Mount ..........................................................................................73
[Link] Silicone Bottom Connector Mount ......................................................................................74
4.8 Route the Main Cable (optional) ...................................................................................... 77
4.8.1 Apply Dielectric Grease ........................................................................................... 78
4.8.2 Protect the Cables and Cable Connectors ................................................................. 79
4.9 Apply Power ..................................................................................................................... 79
4.9.1 Power on the Battery Terminal ................................................................................. 79
4.10 Register the Terminal ....................................................................................................... 80
4.11 Cleaning Instructions ........................................................................................................ 81
4.12 Replacing Lithium Batteries ............................................................................................. 81
5 Troubleshooting the Terminal ......................................................................................... 84
5.1 Terminal Does Not Register or Report ............................................................................. 84
5.2 Shipping Terminals Back ................................................................................................. 84
APPENDIX A Order Part Numbers....................................................................................... 85
APPENDIX B Activation Information ................................................................................... 87
APPENDIX C Reinstalling or Replacing a Terminal ........................................................... 88
APPENDIX D Replacing a Battery Gasket............................................................................ 89
APPENDIX E VHB Rail Bracket Installation ....................................................................... 91
Installation Guidelines ................................................................................................................ 91
Attach the Bracket and Prepare the Surface ............................................................................... 91
Select a Mount Option ................................................................................................................ 94
APPENDIX F IDP-800 Blunt Cut Cable ................................................................................ 98
APPENDIX G Cable Assembly Instructions ....................................................................... 100
Required Tools and Materials ................................................................................................... 100
Cable Assembly Steps .............................................................................................................. 101

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APPENDIX H IDP-800 to IDP-680/IDP-690 Adaptor Cable ............................................. 104

Acronyms/Glossary ................................................................................................................... 106

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List of Figures
Figure 1 IDP-800 with Battery Compartment......................................................................... 14
Figure 2 SkyWave's IsatData Pro Network............................................................................. 15
Figure 3 Remote Standard Antenna Side Connector .............................................................. 16
Figure 4 Remote Standard Antenna Bottom Connector ......................................................... 16
Figure 5 Remote Low Elevation Antenna2 Side Connector.................................................... 16
Figure 6 Activation Magnet Fob on the Magnet Sensor ......................................................... 29
Figure 7 Power On Sequence .................................................................................................. 31
Figure 8 Battery Indicator Sequence (12 seconds) ................................................................. 31
Figure 9 Power Off Sequence ................................................................................................. 31
Figure 10 Already On Sequence ............................................................................................... 32
Figure 11 Mating Terminal Connector Pin Assignment ........................................................... 33
Figure 12 Analog Accuracy by Limiting Voltage Drop on Return Current ............................. 35
Figure 13 Analog Accuracy with Independent Analog Reference ........................................... 36
Figure 14 Pass-Through Mode Signals ..................................................................................... 37
Figure 15 Rechargeable (NiMH) Battery Label ....................................................................... 42
Figure 16 Non-Rechargeable (Li/FeS2) Battery Label.............................................................. 42
Figure 17 Non-Rechargeable Terminal..................................................................................... 42
Figure 18 Rechargeable Terminal ............................................................................................. 43
Figure 19 Battery Protection Circuit (Li/FeS2).......................................................................... 44
Figure 20 Battery Protection Circuit (NiMH) ........................................................................... 44
Figure 21 Charging Flowchart .................................................................................................. 45
Figure 22 Accelerometer Axis .................................................................................................. 48
Figure 23 IDP-800 Top View Enclosure Dimensions .............................................................. 52
Figure 24 IDP-800 Side View Enclosure Dimensions.............................................................. 52
Figure 25 IDP-800 Connector View Enclosure Dimensions .................................................... 52
Figure 26 Remote Standard and Low Elevation Antenna - Bottom View ................................ 53
Figure 27 Remote Standard Antenna Height Dimensions ........................................................ 54
Figure 28 Remote Low Elevation Antenna Height Dimensions ............................................... 54
Figure 29 Mobile ID Location .................................................................................................. 56
Figure 30 Remote Antenna Serial Number Label Location (standard antenna shown) ............ 56
Figure 31 Manage Terminals .................................................................................................... 57
Figure 32 Sample Activation Report ........................................................................................ 57
Figure 33 Remote Antenna Cable Bend Radius ....................................................................... 60
Figure 34 Battery Cover Screws ............................................................................................... 61
Figure 35 Battery Orientation ................................................................................................... 62
Figure 36 Verify Battery Orientation ........................................................................................ 63
Figure 37 Rechargeable Batteries - Voltage Measurement....................................................... 63
Figure 38 Non-Rechargeable Batteries - Voltage Measurement First String ........................... 64
Figure 39 Non-Rechargeable Batteries - Voltage Measurement Second String ....................... 65
Figure 40 Gasket and Gasket Wall ........................................................................................... 65
Figure 41 Battery Cover............................................................................................................ 66
Figure 42 Apply Pressure around the Battery Cover ................................................................ 66

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Figure 43 LED, Target, and Connector Cap ............................................................................. 67

Figure 44 Locking Collar and Key Slot .................................................................................... 67
Figure 45 Activation Magnet Fob ............................................................................................. 68
Figure 46 Accelerometer and Terminal Orientation ................................................................. 69
Figure 47 Air Vent Feature ....................................................................................................... 71
Figure 48 Heat Shrink ............................................................................................................... 72
Figure 49 Air Vent Feature ....................................................................................................... 72
Figure 50 Apply Silicone to Remote Antenna .......................................................................... 73
Figure 51 Heat Shrink ............................................................................................................... 74
Figure 52 Drill Mounting Hole ................................................................................................. 74
Figure 53 Attach Cable to Terminal ......................................................................................... 75
Figure 54 Apply Silicone to Hole in Asset ............................................................................... 75
Figure 55 Apply Silicone to Terminal ...................................................................................... 76
Figure 56 Sample Cable Placement in a Vehicle Cab............................................................... 77
Figure 57 Apply Silicone Lubricant to Connector .................................................................... 78
Figure 58 Cable Connector and Locking Collar ....................................................................... 78
Figure 59 Cable Management ................................................................................................... 79
Figure 60 Battery Cover - Sides................................................................................................ 82
Figure 61 Battery Orientation ................................................................................................... 82
Figure 62 Gasket Hook and Loop Features .............................................................................. 89
Figure 63 Fit Loops over the Hooks ......................................................................................... 90
Figure 64 VHB Rail Bracket and Lanyard................................................................................ 92
Figure 65 Lanyard Attached to Terminal .................................................................................. 92
Figure 66 Assembled Terminal with VHB Rail Bracket and Lanyard ..................................... 93
Figure 67 Installation Location for VHB Rail Bracket and Lanyard ........................................ 94
Figure 68 Rivet Hole Locations ................................................................................................ 97
Figure 69 IDP-800 Blunt Cut Cable ......................................................................................... 98
Figure 70 Face View of IDP-800 Blunt Cut Cable Connector ................................................. 99
Figure 71 Raw Cable Details .................................................................................................... 99
Figure 72 Basic Connector Parts for Soldering Configuration ............................................... 100
Figure 73 Recommended Stripping Length ............................................................................ 101
Figure 74 Cable with Sealing Nut and a Back Shell ............................................................... 101
Figure 75 O-ring ..................................................................................................................... 101
Figure 76 Red Gasket.............................................................................................................. 102
Figure 77 Wires and Solder Cups ........................................................................................... 102
Figure 78 O-Ring over Connector Body ................................................................................. 102
Figure 79 Silicone in the Connector ....................................................................................... 102
Figure 80 Silicone in the Grommet ......................................................................................... 103
Figure 81 Cable Exit Area ...................................................................................................... 103
Figure 82 Assembled Sealing Nut .......................................................................................... 103
Figure 83 IDP-800 to IDP-68/IDP-690 Adaptor Cable .......................................................... 104
Figure 84 IDP-800 Mating Connector End Pin-Out ............................................................... 104
Figure 85 IDP-680/IDP-690 Connector End Pin-Out ............................................................. 105

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List of Tables
Table 1 Satellite Modem Operating Modes ........................................................................... 18
Table 2 Application Controller Operating Modes ................................................................. 18
Table 3 Application Peripherals ............................................................................................ 19
Table 4 Power Modes ............................................................................................................ 19
Table 5 Terminal Temperature .............................................................................................. 23
Table 6 Battery Temperature Specifications ......................................................................... 23
Table 7 External Voltage Input.............................................................................................. 23
Table 8 Operational Power Consumption Values @ 12 V .................................................... 24
Table 9 Power Off Values ..................................................................................................... 25
Table 10 Power Consumption Scenario .................................................................................. 25
Table 11 GPS and GLONASS Power Consumption ............................................................... 26
Table 12 Blockage Power Consumption (Power Profile = MobileMinbattery) ...................... 26
Table 13 Accelerometer Power Consumption Factors ............................................................ 27
Table 14 Supported Sleep Phase Durations ............................................................................. 28
Table 15 Sample Rates ............................................................................................................ 28
Table 16 Magnet Activation Times ......................................................................................... 29
Table 17 Power Input Options ................................................................................................. 30
Table 18 Load Dump Circuitry................................................................................................ 30
Table 19 Inrush Current Specifications @ 12 V...................................................................... 31
Table 20 Reverse Voltage Input .............................................................................................. 31
Table 21 Modem State LED Flashing Patterns ....................................................................... 32
Table 22 Magnetic Switch Trigger Times ............................................................................... 32
Table 23 Terminal Electrical Pin Assignment ......................................................................... 33
Table 24 Input / Output Specifications .................................................................................... 34
Table 25 RF Connector............................................................................................................ 36
Table 26 Pass-Through Mode Power ...................................................................................... 37
Table 27 Pass-Through Mode Timing Specifications ............................................................. 37
Table 28 Pass-Through Mode Power Consumption ................................................................ 38
Table 29 RS-232 Electrical Characteristics ............................................................................. 38
Table 30 Auto RS-232 Power On/Off ..................................................................................... 38
Table 31 Frequency Specifications .......................................................................................... 39
Table 32 Terminal with Integrated Antenna RF Specifications .............................................. 39
Table 33 Remote Standard Antenna RF Specifications........................................................... 39
Table 34 Remote Low Elevation Antenna RF Specifications ................................................. 39
Table 35 Hardware GPS and GPS/GLONASS Specifications ................................................ 40
Table 36 Approved Batteries ................................................................................................... 41
Table 37 Charger Initiation Parameters ................................................................................... 46
Table 38 Battery Temperature Specifications ......................................................................... 46
Table 39 Charging Stage Specifications .................................................................................. 47
Table 40 Accelerometer Specification..................................................................................... 49
Table 41 Nonvolatile Storage .................................................................................................. 49
Table 42 IDP-800 Terminal and Bracket Mass ....................................................................... 52

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Table 43 Antenna Mass and Material ...................................................................................... 54

Table 44 Order Part Numbers - Hardware GPS ...................................................................... 85
Table 45 Order Part Numbers - GPS/GLONASS .................................................................... 85
Table 46 Order Part Numbers - Antenna ................................................................................. 86
Table 47 Order Part Numbers - Replacement Parts and Kits .................................................. 86
Table 48 IDP-800 Mating Blunt-Cut Cable Color Code ......................................................... 99
Table 49 Cable Connector Pin-Out........................................................................................ 105

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Preface
Purpose
This document is as an overview of the installation procedures and hardware
characteristics and specifications for the IDP-800 terminal.

Audience
This document is for technical readers. It provides information to ensure successful
installation and operation of IDP-800 terminal.

Errata Sheet
Refer to the Customer Support website for updates or for an Errata Sheet that might be
available after the release of this document. Always check the website for the most
current documentation.

Notation
Unless noted otherwise, references to GPS include GLONASS.
Hardware components and hardware labels in this document may not be exactly as shown
and are subject to change without notice.
CAUTION This safety symbol warns of possible hazards to personnel,
equipment, or both. It includes hazards that will or can cause
personal injury, property damage, or death if the hazard is not
avoided.
Note: A note indicates information with no potential hazard. A note indicates points
of interest or provides supplementary information about a feature or task.
Numbered lists indicate a series of steps required to complete a task or function.
Bulleted lists highlight information where order or sequence is not crucial.

Reference
The content of the following documents may be useful in conjunction with this guide.
These documents are available from the downloads section at [Link] or
from the IDP Toolkit, which is also available from the website.
[T202] IDP Terminal API Reference
[T204] IDP Terminal User Guide

Battery Safety Warnings

CAUTION Replace depleted batteries only with the batteries specified in
Section 3.8.1. Do not use any other battery chemistry.

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CAUTION Under no circumstance should you recharge Energizer® Ultimate

Lithium batteries. Severe personal injury, death, or substantial
property damage is possible.
CAUTION Always follow local disposal guidelines when disposing of
lithium batteries. Refer to the manufacturers' website (product
safety datasheet) for information on proper disposal of lithium
batteries.
CAUTION Do not short circuit or expose batteries to temperatures above the
maximum rated temperature as specified by the manufacturer.
Do not puncture or crush.

Product Safety Datasheets

Refer to the manufacturers' website for specific battery details and safety precautions,
including handling and shipping.
Energizer Non-rechargeable Lithium Iron Disulfide (Li/FeS2):
[Link]
[Link]
Tenergy Rechargeable Nickel Metal Hydride (NiMH):
[Link]
%[Link]
[Link]

Safety Disclaimer
SkyWave makes no warranties, representations or guarantees that the products and
network services are suitable for any use in any hazardous environments requiring fail
safe performance (including without limitation marine safety and distress systems,
operation of nuclear facilities, aircraft navigation or communications systems, weapons
systems, air traffic control and life support services) or any other application in which the
failure of the products or network services could result in death or personal injury.
Solution Providers assume all liability associated with selling any products and network
services for any such applications, and Solution Provider will defend, indemnify, and
hold SkyWave harmless against any claims against SkyWave for loss, damage, liability,
or expense (including lawyers’ fees) arising out of or related to the sale by Solution
Providers or any Solution Provider Reseller, or the user by any end user, of any product
or network service.
Please read all cautions and warnings throughout this document.

Safety Precautions
The terminal must comply with all safety precautions relating to the operation, usage,
service and repair of the terminal. SkyWave assumes no liability for the customer’s
failure to comply with any of these precautions.

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Caution warnings appear throughout this document.

Installation Warning
SkyWave recommends that this product be installed by the authorized distributor from
whom it has been purchased. By carrying out the installation of the product, the installer
assumes exclusive responsibility for, and agrees to indemnify SkyWave from, any injury
or damage of any kind arising from the installation.

Installer Responsibility
The installer is responsible for all injuries or damages arising out of or relating to any
wrongful or negligent act or omission of the installer (and/or any subcontractors) in
connection with the installation of any SkyWave product, except any such injuries or
damages arising solely from a defective SkyWave product. In addition to the liability
imposed upon the installer on the account of personal or property injury or damage,
bodily injury, including death, suffered as a result of the installer’s wrongful or negligent
installation of any SkyWave product, the installer assumes the obligation to defend,
indemnify and hold SkyWave harmless, including its directors, officers, employees,
agents and assigns, and to indemnify SkyWave, including its directors, officers,
employees, agents and assigns, from and against every damage, expense, liability or
payment arising out of or relating to such wrongful or negligent act or omission,
including legal and court fees. The installer also agrees to defend, indemnify and hold
SkyWave harmless, including its directors, officers, employees, agents and assigns, from
and against any wrongful or negligent act or omission committed by any subcontractor or
other person employed by or under the supervision of the installer for any purpose in
connection with the installation of SkyWave products, and to indemnify SkyWave,
including its directors, officers, employees, agents and assigns, from every damage,
expense, liability or payment arising out of or relating to such wrongful or negligent act
or omission, including legal and court fees. Every right, defence, and/or indemnity of
whatsoever nature applicable to SkyWave shall also be available and shall extend to
benefit and to protect the SkyWave’s directors, officers, employees, agents and assigns
and for such purposes SkyWave is or shall be deemed to be acting as agent or trustee on
behalf of and for the benefit of such companies and persons.

Limited Liability
SkyWave’s liability is limited to the cost of repair or replacement of any of SkyWave’s
products during the warranty period. To the maximum extent permitted by applicable
law, SkyWave's total liability for damages of any kind, whether based on breach of
contract, tort (including negligence), product liability, incidental, special, consequential,
indirect or similar damages with product application and usages will be limited to an
amount equal to the product's original price paid by the Purchaser to SkyWave and this
limitation of liability is reasonable given the price of SkyWave's products. In no event
will SkyWave be liable to the Purchaser, any resellers of the Purchaser or any end user
for any lost profits or savings, lost business, loss of data, any telecommunications
breakdown, unavailability, downtime, interruption or delay, any suspension of service by
any third party service provider including Inmarsat or any incidental, special, indirect, or
consequential damages, whether based on breach of contract, tort (including negligence),

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product liability, incidental, special, consequential, indirect or similar damages and

whether or not SkyWave has been advised of the possibility of such occurrence or
damage. The parties agree that the foregoing represents a fair allocation of risk
hereunder.

Warranty
SkyWave provides a manufacturer’s warranty to the original purchaser (Solution
Provider) that its products and services will perform in accordance with SkyWave’s
specifications and will be free from defects in material and workmanship for a limited
period of time. This warranty is limited to the repair and/or replacement of any defective
components experienced under normal specified operating use and storage conditions, at
SkyWave’s discretion. It does not cover any damages caused or associated with the
product’s misuse. Please check your Solution Provider agreement for warranty details
and conditions. The end-user’s only remedy or recourse is against the Solution Provider,
and any experience with defective products should be communicated to your Solution
Provider. Shipping of defective product, back to the Solution Provider will be in
accordance with the Solution Provider’s instructions and should be accompanied with a
fault report. SkyWave is not responsible for corrosion damage caused by improperly
assembled or installed cables. Warranty is void if unit is opened.
A fault report is required for each unit returned under warranty. Please contact
SkyWave’s Customer Support for additional information.

User Serviceable Parts

The terminals contain no user serviceable parts or replaceable fuses.

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1 Product Overview
The IDP-800 low profile terminal contains an integrated antenna, an application card, a
satellite modem for communicating with the satellite, a panel connector for external
power input, RS-232, three (3) configurable input/output ports and; a serviceable battery
compartment. The terminal is also available with an SMA rather than an integrated
antenna for applications requiring a remote antenna.
There are two configurations of the terminal; a rechargeable model and a non-
rechargeable model. Figure 1 shows the IDP-800 with battery compartment.
Figure 1 IDP-800 with Battery Compartment

The terminal's enclosure is made of a rugged, impact and chemical resistant plastic
material providing UV resistance.
The IDP terminal is designed for industrial and fixed applications or to be mounted
outdoors on a wide range of mobile platforms such as vehicles or boats.
The terminal’s built-in programmability allows it to work as a stand-alone data-
messaging terminal, with built-in I/O data collection and processing capabilities. Feature-
rich software tools make programming easy and shorten the design and testing time.

1.1 Overview of the Messaging System

SkyWave's IsatData Pro satellite messaging system is designed to support the
management of mobile or fixed assets located around the world. An asset fitted with one
of SkyWave's satellite based mobile terminals can have its status and location monitored,
as well as send large messages.
The network provides the following key features and benefits:
• Polling of terminal status and location
• Scheduled reporting of terminal status and location
• Transmission of text messages to and from a serial port on the terminal
• Two-way communication for messaging to and from the asset for near real-time
control
• Up to 6,400 bytes from-mobile messages
• Up to 10,000 bytes to-mobile messages

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• Broadcast messages
• Default acknowledged messages
• Global service
Figure 2 SkyWave's IsatData Pro Network

Inmarsat
Satellite

GPS
Satellites

Internet

IDP PC
Gateway Land Earth
Solution Terminals
Station (LES)
Provider’s Site

Service is provided to end users by Solution Providers (SPs) who use the SkyWave
IsatData Pro network to offer particular applications and/or services to their clients. The
SPs link their application services to the satellite terminals by connecting to the IsatData
Pro gateway. This acts as the communications hub of the system, routing traffic to and
from the terminals and the various service providers.
Configuration and data retrieval from the terminal can be easily accomplished through
Internet-based application services provided by SPs or by integrating existing customer
enterprise software to receive information from the Gateway.

1.2 Terminals1
The IDP-800 mobile satellite terminal operates on the SkyWave IsatData Pro network.
Terminals include an omni-directional (integrated or remote) antenna, satellite modem,
GPS, programmable microcontroller, a side connector and three I/O (input/output) feeds
capable of monitoring and controlling external sensors and devices.
Terminals operate either with rechargeable or non-rechargeable batteries, or external
power.
The terminal's built-in programmability allows it to work as a stand-alone terminal with
built-in I/O data collection and processing capabilities. Each model is suitable for both
mobile and fixed installations.

1
Hardware components may not be exactly as shown in this document.

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Feature-rich software tools make scripting easy, and shorten the script design and testing
time. SkyWave also provides consulting services to SPs to help program the terminals
and get customer applications running quickly. Part numbers are shown in Table 44.

1.3 Remote Antennas

The IDP-800 supports two optional remote satellite antenna models: the standard antenna
with an elevation angle of 20 to 90° and the low elevation antenna from -15 to 90°.
Antennas are available with a side or bottom connector and have four mounting tabs for
installation. The bottom connector antenna configuration is intended for through-hole
installation where the cable connection is inside the asset protected from moisture.
CAUTION Painting the antenna may interfere with its performance.

Figure 3 Remote Standard Antenna2 Side Connector

Figure 4 Remote Standard Antenna Bottom Connector

Figure 5 Remote Low Elevation Antenna2 Side Connector

CAUTION The DMR-800/SureLinx antenna is not electrically compatible

with the IDP-800. Both the antenna and the SureLinx or
IDP-800 can be damaged if connected to the incorrect antenna.

2
Cable length for illustration purposes only

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The remote antenna assembly is an active satellite antenna. It uses a DC voltage on the
coax cable. The DC voltage powers a low noise amplifier for the satellite/GPS receiver
and a power amplifier for the satellite transmitter.
Each remote antenna connects to the terminal using low loss coax cable terminated with
an industry standard SMA connector. The antenna assembly contains no user serviceable
parts.

1.4 Terminal Key Features and Benefits

CAUTION Do not rely solely on the terminal for emergency (SOS) calls.

The IDP-800 terminal has the following key features and benefits:
• External power input
• Motion detection/accelerometer
• Magnetically activated power on/off switch
• Panel connector: external power input, serial RS-232 interface and three (3)
configurable (analog/digital) I/O
• Serviceable battery compartment
• Built-in GPS/GLONASS receiver to calculate position, speed and heading
• Quick and easy installation reduces labor time and costs
• Ships with installed firmware
• Flexible custom scripting
• Rugged construction

1.5 Pass-Through Mode

The terminal operates in pass-through mode when there is no valid application firmware
present. In pass-through mode, the terminal connects the external RS-232 port to the
serial port on its internal modem, making the terminal an IP67 modem that accepts a wide
input voltage. The terminal retains all of its certifications while operating in pass-through
mode.

1.6 Operating Modes

The terminal operates in a number of modes while the application processor portion of
the terminal has its own independent set of modes.

1.6.1 Satellite Modem

For the most part, the satellite modem operates independently of the application
controller. Consequently, power consumed by the satellite modem must be added
separately to determine a terminal's overall power consumption.

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Table 1 Satellite Modem Operating Modes

Operating Mode Description
Transmit Mode In transmit mode the modem is transmitting a signal to the
gateway.
Receive Mode In receive mode the modem is attempting or actively listening to
the satellite (listening on the bulletin board channel or on a traffic
channel).
Sleep Mode This is the power mode when the modem turns itself off between
wake-up intervals. Both the terminal and gateway track the wake-
up interval. Consequently, when a terminal is in sleep it does not
miss incoming messages. If a modem has a message to send, it
automatically exits sleep mode without waiting for the next
wake-up interval.
Idle Mode With IsatData Pro, a modem receives messages in one of the 10
half second sub-frames. Idle mode is when the modem turns off
its receiver waiting for its next assigned sub-frame. The modem
automatically enters Idle mode on its own, independent of the
application.

1.6.2 Application Controller

The application processor portion of the terminal has its own independent set of modes.
Table 2 Application Controller Operating Modes
Operating Mode Description
Processing In Processing mode the Lua services are actively running.
Power Save In this mode the application processor is waiting for events. With
properly designed applications the application processor spends
most of its time in this mode.
Power Off In this mode the application processor and modem are both
powered off. All terminal peripherals are off as well.

1.6.3 GPS/GLONASS
The GPS/GLONASS can be powered on independently of the satellite modem operating
modes in Table 1. The IDP terminal can be configured to operate in either GPS or
GPS/GLONASS with GPS as the default. Refer to APPENDIX A for part numbers.

1.6.4 Accelerometer Modes

Refer to [T202] for acceleration mode details.

1.6.5 Application Peripherals

These peripherals are either on/off. Power consumption is affected when they are
powered on.

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Table 3 Application Peripherals

Operating Mode Description
RS-232 On/Off When the RS-232 is on the RS-232 transmit driver is enabled
and the serial clocks are active.
LED On/Off The LED can be enabled by the software.
I/O Active/Inactive The I/O can be configured as an input or output.

1.6.6 Power Modes

Table 4 Power Modes
Power Mode Description
Discharge In this mode the terminal is powered by the installed batteries.
The terminal monitors battery voltage and disconnects the
battery from the terminal when the voltage falls below the
minimum allowed for the chemistry installed.
Charge In Charge mode the terminal operates from external power and
charges the installed rechargeable batteries if the ambient
temperature falls within the battery charge temperature range.
External The terminal is operating from external power. It never charges
(not charging) a non-rechargeable battery. Rechargeable batteries are not
charged if the battery is topped up or the battery temperature is
out of range.

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2 Compliance
The IDP-800 terminal has obtained the following certifications:

Inmarsat Type Approval

Industry Canada
• RSS-170, Issue 2, Spectrum Management and Telecommunications Policy,
Radio Standard

FCC Part 15

FCC Part 25 - E100192

• FCC ID: B92IDP1XX
• CFR Title 47: Telecommunication, Part 25 - Satellite Communications
• OET 65 - Radiation Safety
CAUTION Mount the terminal with
integrated antenna at
least 25 cm away from humans.

SAE J1455
• Resistance to oil and other chemicals (clause 8.5)

R&TTE Directive 1999/5/EC (CE Mark)

• EN 301 426 V1.2.1 (2001-10), Satellite Earth stations and Systems (SES);
Harmonized EN for Low data rate Land Mobile satellite Earth Stations (LMES)
and Maritime Mobile satellite Earth Stations (MMES) not intended for distress
and safety communications operating in the 1,5/1,6 GHz frequency bands
covering essential requirements under article 3.2 of the R&TTE Directive
• EN 301 489-20 V1.2.1 (2002-11), Electromagnetic compatibility and Radio
spectrum Matters (ERM); ElectroMagnetic Compatibility (EMC) standard for
radio equipment and services; Part 20: Specific conditions for Mobile Earth
Stations (MES) used in the Mobile Satellite Services (MSS)
• EN 301 489-1 V1.9.2 (2011-09) - Electromagnetic compatibility (EMC)
• IEC 60950-22:2005 (1st Edition) - Safety
• IEC 60950-1:2005 (2nd Edition); Am 1:2009
CAUTION This certification is void if batteries other than those
specified in Section 3.8.1 are used.
• IEC 62311 - Radiation safety

Ingress Protection IEC 60529

Transceiver and Battery Compartment: IP67

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IEC 60945
Compliant with the following sections of IEC 60945 (2002) - Maritime navigation and
radio communication equipment and systems:
The normal input voltage for IEC 60945 compliance is declared as 12/24 V. With this
nominal input voltage, the IDP-690 meets IEC 60945 requirements for power supply
operation of -25%/+30% (9 to 32 V).
Equipment Performance N/A
Dry Heat IEC 60945 Section [Link], IEC60068-2-2
Low Temperature IEC 60945 Section [Link], IEC60068-2-1
Humidity IEC 60945 Section 8.3, IEC60068-2-30
Vibration IEC 60945 Section 8.7.2, IEC60068-2-6
Insulation Resistance IEC 60945 Section 8.3 and 8.4, IEC60092-504
Power Supply Variation IEC 945 Section 10.7.1 and 10.7.2, IEC60092-504
Power Supply Failure IEC 945 Section 10.8.2, IEC60092-504
Acoustic Noise IEC 60945 11.1.2
Compass Safe Distance IEC 60945 11.2.2
Compass Safe Distance 20 cm
Salt Mist IEC 945 Section 8.12, IEC 60069-2-52 Severity 1
Radiated Emissions EN 55016-2-3:2006
Radiated Immunity IEC 61000-4-3:2006 + A1:2008
Conducted Emissions EN 55016-2-1:2009
Conducted Immunity IEC 61000-4-6:2009
Fast Burst Transients IEC 61000-4-4:2004
Electrostatic Discharge IEC 61000-4-2:2009
Surge (Applicable to AC IEC 61000-4-5
powered equipment)

RoHS
Restriction of Hazardous Substances (RoHS)3
Battery components are excluded from the 2002/95/EC RoHS Directive. Details as
per Energizer® are noted below.
The Waste Electrical and Electronic Equipment (WEEE) Directive: Batteries are
not covered by the WEEE Directive because according the WEEE Directive (art.
6.1 Treatment and its annex II) “batteries should be removed from any separately
collected WEEE.” When removed the batteries are then covered by the specific
Directive 91/157/EC and also the Technical Adaptation (TA) 98/101/EC.
RoHS: RoHS language listed below.

3
European Union's (EU) Directive 2002/95/EEC "Restriction of Hazardous Substances" (RoHS)
in Electronic and Electrical Equipment.

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9) This Directive should apply without prejudice to Community legislation

on safety and health requirements and specific Community waste
management legislation, in particular Council Directive 91/157/EEC of 18
March 1991 on batteries and accumulators containing certain dangerous
substances 14.

RCM Australia
The following compliance marks, C-Tick, A-Tick, and RCM have been consolidated
into a single RCM mark.

Australian Communications and Media Authority (ACMA)

• AS/CA S042.1:2011 (Requirements for Connection to an Air Interface of a
Telecommunications Network - Part 1: General)
• AS/NZS 60950.1 (2011) + Amendment 1 (2013) (Information Technology
Equipment - Safety)
• AS/NZS CISPR 22:2009 + A1 (2010) (CLASS B) (Information Technology
Equipment - Radio Disturbance Characteristics )
• Radiocommunications (Electromagnetic Radiation – Human Exposure) Std 2003
• Radiocommunications (Communication with Space Object) Class License 1998
with variation 2003 (No. 1)

4
European directive OJ L 78, 26.3.1991, p. 38. Directive as amended by Commission Directive
98/101/EC (OJ L 1, 5.1.1999, p. 1).

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3 Specifications
3.1 Temperature
3.1.1 Terminal Temperature
Operating temperature with batteries is shown in section 3.1.2.
Table 5 Terminal Temperature
Parameter Part Number
Operating Temperature
excluding batteries -40 to +85°C
Storage Temperature
excluding batteries -40 to +85°C

3.1.2 Battery Temperature

The IDP-800 has been tested and certified based on the batteries. Table 6 defines the
battery's temperature specifications from the manufacturer's datasheet.
Table 6 Battery Temperature Specifications
Rechargeable Batteries Non-Rechargeable
Batteries
Battery Chemistry NiMH5 Li/FeS26
Approved Manufacturer Tenergy Energizer
Part Number 10321 L91 (Ultimate Lithium)
Charge Temperature Range 0˚C to +45˚C N/A
Operating Temperature Range -10°C to +50°C -40°C to +60°C
Storage Range -20°C to +30°C -40°C to +60°C
Note: For optimal battery life, terminals with batteries installed should not be stored
above 40°C for extended periods.

3.2 Electrical
3.2.1 External Voltage Input
Table 7 External Voltage Input
Parameter Part Number
Power Supply Voltage 9 to 32 V DC

5
[Link]
6
[Link]

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3.2.2 Operational Power Consumption

Table 8 shows the typical power consumption values at room temperature (22°C) with an
external 12 V supply except where otherwise indicated for a normal operating terminal.
Power Off values are shown in Table 9.
In order to calculate a terminal's total power, add the current consumption in the
terminal's mode of operation, the modem's mode of operation and the sum of all
peripheral current consumptions.
One of the peripherals is RS-232. It is important to note that if the RS-232 is connected,
the RS-232 default configuration is for the terminal to remain in Processing mode and
never enter Power Save mode. Consequently, it is very important not to connect the
RS-232 for power sensitive applications or to manage the RS-232 settings appropriately.
Refer to [T202] for details.
The charger can operate in any terminal mode including Power Off.
Table 8 Operational Power Consumption Values @ 12 V
Terminal Mode of Operation Current
Processing 10 mA
Power Save 115 µA
Modem Mode of Operation Current
Transmit 860 mA
Receive 38 mA
Sleep 95 µA
Idle 38 mA
Peripheral Current
RS-232 By default if RS-232 is connected, Power
Save is not used. Minimum power
corresponds with Processing mode.
LED 50 mA
Accelerometer Current
Full operation 139 µA
Low power mode 7 µA
Shutdown 0.5 µA
Battery Charging Current (Typical)
Charger on (12 V) 1220 mA
Charger on (24 V) 550 mA
Charger on (32 V) 420 mA
Refer to section [Link] for GPS and GPS/GLONASS power consumption values.
The IDP-800 can be operating in a Power Off mode. In Power Off the terminal, modem
and all peripherals are turned off. If the terminal is in Power Off mode, then all
peripherals are off and the current draw is zero (0).

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Table 9 Power Off Values

Power Off Current
Power Off 11.6 µA (battery power)
17 µA (external power)

[Link] Power Consumption Scenario

Power consumed by the IDP-800 is fairly involved. A Power Estimator is available from
the Customer Support website7 to help customers estimate power and battery life for their
particular applications.
Note: By default the IDP-800 does not ship with a wake-up interval or battery profile.
These must be properly configured to obtain battery life as defined below.
As an example, Table 10 shows the estimated power consumption for an IDP-800
operating in two difference scenarios.
Table 10 Power Consumption8 Scenario
Parameter Example 1 Example 2
Power Profile MobileBattery MobileBattery
Wakeup interval 60 minutes 60 minutes
Battery type Non-rechargeable Rechargeable
(Energizer) (Tenergy)
Temperature for de-rating 40°C 40°C
Scheduled reports with GPS Once per day 96
(every 15 minutes)
Message size Short messages Short messages
(<25 bytes) (<25 bytes)
Blockage Condition Never blocked Never blocked
Calculated Value - 22°C Results
Average current (mAh/day) 4.9 65
Battery life (months) 36 1
Battery life (years) 3.0 0.1
Calculated Value - Temperature De-rated Results
Average current (mAh/day) 6 66
Battery life after de-rating temperature 26 0.83
(months)
Battery life after de-rating temperature 2.2 0.1
(years)

7
To access the power estimator utility, log onto [Link] and
select Online Utilities.
8
To access the battery calculator utility, log onto [Link] and
select Online Utilities.

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[Link] GPS and GLONASS Power Consumption

Power consumption values for GPS and GLONASS are shown in Table 11.
Table 11 GPS and GLONASS Power Consumption
Parameter Hardware GPS GPS/GLONASS
GPS GPS GLONASS
Current 40 mA @12 V 30 mA at 12 V 28 mA at 12 V

[Link] Blockage Power

If the IDP-800 terminal is blocked so that it cannot receive the satellite signal, it attempts
to reacquire the signal by proceeding through several stages of recovery. With increased
time in blockage, the duration of the time between scans for a satellite signal increases
typically doubling with each unsuccessful attempt. The objective is to recover in a timely
manner without excessive power consumption. Refer to [N200] for additional details on
network blockage behavior.
The IDP-800 power consumption during blockage is characterized in Table 12. The
values in Table 12 assume:
• MobileMinBattery (#4) power profile
• Two maximum GPS time settings
• Non-rechargeable terminal
The table shows power consumption with the GPS time set for 3 minute and 1 minute.
The GPS fix time is a modem register that limits the amount of time the terminal waits
for a GPS fix. A long GPS fix time as per the 3 minute default allows time for the GPS to
acquire a signal in a partially blocked location. However, GPS consumes considerable
power and shortening the acquisition time saves power if the terminal is blocked and will
never acquire a GPS fix. The GPS fix time can be restricted by two properties
maxFixTimeout (PIN 20) and acquireTimeout (PIN 19) in the Position service (SIN 20).
maxFixTimeout defines the timeout for any fix while acquireTimeout defines the timeout
for the GPS to see at least one satellite.
Table 12 Blockage Power Consumption (Power Profile = MobileMinbattery)
Multiplier of Baseline Power Consumption
(Baseline: 1 report/day in unblocked condition)
Blockage Mode Check Interval for 3 Minute 1 Minute
Blockage Recovery Maximum GPS Maximum GPS
Acquisition Time Acquisition Time
Short Term Blockage 5 to 40 minutes. 5.5 times Baseline
(First 2.3 hours of Interval starts at 5 and
blockage) doubles each attempt.
Medium Term Blockage 40 minutes to 24 hours. 1.9 times Baseline 1.0 times Baseline
(2.3 hours to 68 hours of Interval starts at 40 minutes
blockage) and doubles each attempt.
Long Term Blockage 24 hours 1.2 times Baseline 0.8 times Baseline
(more than 68 hours)

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A consequence of the blockage algorithm is that the longer the terminal is blocked, the
longer it takes for the terminal to detect that the blockage condition has been removed.
However, an application could use external events such as digital I/Os (i.e., connected to
ignition) to force the terminal to force new satellite channel search if movement is likely
to have occurred.
The satellite traffic channel check can be forced by writing any value, including the
current value to the modem’s wake-up interval. It is important that the application not
write to the wake-up interval frequently, as each write triggers a search which consumes
significant power. When the application forces a check by writing to the wake-up
interval, the terminal blockage algorithm resumes normal operation if the traffic channel
is correctly received. If the terminal cannot find the traffic channel after the search, the
terminal resumes the blockage algorithm.
A satellite traffic channel check can also be forced by changing the power mode. In this
case, the blockage algorithm restarts all the timers and starts again if traffic channels are
not detected.

[Link] Accelerometer Power Consumption

The power usage of the accelerometer depends on the factors in Table 13.
Table 13 Accelerometer Power Consumption Factors
Parameter Description
Sleep Duration This controls the duration of the power-off interval used by
the accelerometer hardware to save power. If non-zero, the
accelerometer hardware performs the normal sample
processing required for event detection followed by a sleep
period in which the device is suspended to conserve power
[T202].
Sample Rate The sample rate setting controls the sample rate of the
accelerometer hardware. Using a high sample rate reduces
missed events at the expense of power consumption and
CPU processing time [T202].
Event Detectors The creation/configuration of event detectors can have a
large impact on the power-consumption of the terminal.
Setting up detectors that do not require any software based
post processing result in the lowest power consumption.
Setting up multiple thresholds with multiple durations
which requires post processing keeps the accelerometer and
CPU running longer.
Active Sample Buffer The creation/configuration of event detectors can have a
Handles large impact on the power consumption of the terminal.
Setting up detectors that do not require any software based
post processing will result in the lowest power
consumption. Setting up multiple thresholds with multiple
durations which require post processing keep the
accelerometer and CPU running longer.

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The table below shows the supported sleep phase durations. For a mapping to the
accelerometer sleepDuration property, refer to [T202].
Table 14 Supported Sleep Phase Durations
Sleep Phase Duration (ms) Average Current Consumption (uA)
None 129
0.5 100.5
1 78.8
2 55.0
4 34.5
6 25.2
10 16.4
25 7.4
50 4.0
100 2.3
500 0.9
1000 0.7

Sampling Rates
The tables below specify the sample rates supported by the accelerometer hardware.
Refer to [T202] for sampleRate property mapping.
Note: Caution must be taken when using sampling rates above 125 Hz.
Table 15 Sample Rates
Sample Rate (Hz) Bandwidth (Hz) Update Interval (ms)
15.625 7.8125 64
31.25 15.625 32
62.5 31.25 16
125 62.5 8
250 125 4
500 250 2

3.2.3 Power off Controls

The IDP-800 contains a hall-effect sensor which is located under the three concentric
circles etched in the top of the IDP-800. A magnet can be applied to the center of the
three circles (magnet sensor) allowing the IDP-800 to enter or exit Power Off mode
(Figure 6).

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Figure 6 Activation Magnet Fob on the Magnet Sensor

Table 16 provides magnet activation times to control the terminal.

Table 16 Magnet Activation Times
Parameter Value
Time for Power On 3s ≤ time < 10s
Time for Power Off ≥10s
When valid magnet activation is received, the LED responds indicating either:
• Pass-through mode
• Terminal is Powering On
• Terminal is Already Powered On
• Terminal is Powering Off
• Error detected

3.2.4 Power Input Options

The terminal can be powered in a number of ways depending on the application as
follows:
• External power only
• Internal battery only
• External and internal battery power
Table 17 defines the IDP-800's operating mode as a function of the external voltage and
internal voltage. As external and input voltages change, the terminal has an automatic
switchover that does not affect the terminal's operation.
In order to preserve battery life, it is recommended you use external power whenever
configuring and programming the terminal.

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Table 17 Power Input Options9

Terminal Mode External Voltage Internal Battery Terminal Power
Voltage Source
Power Off < PowerOffThreshold Input < 5.9 (non- N/A
rechargeable)
Input < 11 V
(rechargeable)
Power Save or > PowerOffThreshold Any input External Battery
Processing
Power Save or < PowerOffThreshold > 11 V Internal Battery
Processing (rechargeable)
> 5.9 V (non-
rechargeable)
In Power Off, the rechargeable battery has a 11 V threshold to provide deep discharge
protection for the battery. There is no deep discharge protection for the non-rechargeable
battery.

3.2.5 Load Dump Circuitry

External power connected to the terminal passes through a load dump protection circuit.
Load dump meets SAE J1455.
Table 18 Load Dump Circuitry
Parameter Voltage
External input disconnect voltage > 32 V DC
Absolute maximum input +150 V
Input shutdown voltage 8 V minimum

3.2.6 Fuse
The IDP-800 terminal has two internal fuses. The internal fuses provide protection in the
event of an internal power supply failure. The internal fuses cannot be reset and are not
field repairable.

3.2.7 Inrush Current

Inrush current transients occur when the terminal is:
• First powered on.
• Preparing for transmit. This is when the modem's internal voltage switches from
3.4V to 6.3 V.
• Terminal starts to transmit. This is when the antenna's power amplifier is turned
on.

9
Values apply to firmware 4.x.

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Table 19 Inrush Current Specifications @ 12 V

Parameter Specification
Peak Current (A) 12
Duration (ms) (A) 2.5
Average Current (A) 2.6

3.2.8 Reverse Voltage Input

Table 20 Reverse Voltage Input
Parameter Voltage
Reverse Voltage Input -40 V DC (max.)

3.2.9 LED
The terminal has a red LED to indicate that the terminal has successfully powered on or
powered off.
Figure 7 and Figure 8 show the LED flashing sequence for power on.
Figure 7 Power On Sequence
Second 0 1 2 3 4 Meaning
Power on: 1s/5s

Figure 8 Battery Indicator Sequence (12 seconds)

Second 5 Second 6… Sec 7…16 Meaning
Terminal
… Booting/Battery OK
Battery Requires
Charging/Error
To power off the terminal, apply the magnet for over 10 seconds. If the terminal was
powered, you will see the Already On Sequence – continue to apply the magnet until the
power off sequence starts.
Figure 9 Power Off Sequence
Second 10 Second 11 Second 12 Meaning
Sec 0..9 … Turning off
500ms/1s
In the case when the magnet is applied to an already powered terminal for more than 2
seconds, but less than 5 seconds, and the terminal is powered, the sequence is as per the
figure below. If you leave the magnet on for more than 6 seconds, you will power on the
terminal.

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Figure 10 Already On Sequence

Second 2 Second 3… Second Meaning
4…7
2 Terminal On
…
s
Battery Requires
Charging/Replaceme
nt
When the terminal firmware is up and running along with the Lua Services Framework,
the LSF or a user application can be set to control the LED. The ledControl property
[T202] of the system service is used for this purpose.
When the LED is under the control of the LSF, the flashing patterns shown in table below
are used to indicate the current state of the modem.
Table 21 Modem State LED Flashing Patterns
Modem State Flashing Pattern Class-Subclass10
Power on As per above -
Waiting for GPS 3 flashes every Class 3, Subclass 1, Field 19,
fix 30 seconds Flags = Need GPS Fix
Registration in 2 flashes every Occurs when Need GPS Fix flag is cleared
progress 30 seconds (Class 3, Subclass 1, Field 19)
Connection online 1 flash every 30 Occurs when registered flag is set and at
seconds least 1 minute of metrics are available (Class
3, Subclass 17) and the percentage of
successful receives is > 75%
Connection offline 4 flashes every Occurs when the percentage of successful
30 seconds receives (Class 3, Subclass 17) falls below
25% and/or Satellite Control State (Class 3,
Subclass 1, and Field 22) is set to 3.

[Link] LED-Magnet Interaction

Table 22 shows the magnetic switch trigger times for the IDP-800 terminals.
Table 22 Magnetic Switch Trigger Times
Purpose Trigger Time Action Occurs/LED Feedback
Already On 2s<5s Upon magnet detect (>2 s)
Power On 6 s < 10 s After magnet removal (6-9 s)
Power Off 10 s After 10 s, magnet position
irrelevant

10
Refer to [T203] for details.

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Already on begins as soon as the minimum time (magnet detect) threshold is reached
(2 seconds) so the magnet fob can be removed as soon as the LED flashing pattern
begins.

[Link] User Control

After power on and ignition the user has the ability to control the LED by configuring the
LED Control property to 1. The firmware supports a function call (ledControl) that
defines this operation. The user can specify on time (msec), period (msec), and number of
repetitions (0 - 65535 where 0 signifies repeat forever).
This function allows a user service to flash the LED over a short period of time. The user
service is responsible for repeating this short pattern over a longer period. As an example,
using the connection offline case from the previous section, the LED control API allows
a user service to flash the LED four times; the service is responsible for setting a timer
allowing it to restart this pattern every 30 seconds.

3.2.10 Power Connector

The terminals use a circular 7-pin connector.
Parameter Part Number
Mating Connector Kit ST100137

[Link] Connector Pin-out

Figure 11 Mating Terminal Connector Pin Assignment

Table 23 Terminal Electrical Pin Assignment

Pin Functionality Pin Functionality
1 GND 2 RS-232 Rx
3 RS-232 Tx 4 I/O 01
5 I/O 02 6 VIN
7 I/O 03

3.2.11 Input / Output

The terminal's three (3) configurable I/O lines each operate independently in one of
following modes:
• Digital input with weak (1 MΩ) pull down

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• Digital input with 30-50 kΩ pull down

• Digital input with 30-50 kΩ pull-up
• Analog input with weak (1 MΩ) pull-down
• Digital output – push-pull
• Digital output – open drain switch-to-ground with weak (1 MΩ) pull-down
• Disabled (equivalent to analog input)
The I/O lines are functionally interchangeable in every way except for the feature below:
• I/O 03 has dedicated over current/short circuit protection circuitry when operated
in the open drain, switch-to-ground mode. The other I/O lines do not have this
circuitry, so I/O 03 is recommended for applications requiring over current/short
circuit protection.
Each of the three configurable I/O lines has an identical block of circuitry that provides:
• Input voltage clamping
• Filtering
• Switch-to-Ground for loads up to 250 mA
Each of the configurable I/O lines can generate an interrupt in order to wake up the
processor from the Power Save mode. To generate the interrupt, the interrupt line should
be configured and enabled.

[Link] Input / Output Specifications

Table 24 Input / Output Specifications
Parameter Min Type Max Units
Digital Input
Input low range -10 - 1.05 V
Input high range 1.95 - 150 V
Input current, pull-up/pull down disabled (weak 1 MΩ - 4.5 - µA
pull down still in place); Vin = 3.0V. Max. 6 µA at
Vin=32 V.
Input source current, pull-up enabled, Vin = 0V - 75 - µA
Input sink current, pull down enabled, Vin = 3 to - 81 - µA
150V
Digital Output (Push-Pull)
Output high voltage – open circuit 2.65 3.0 3.15 V
Output high voltage (sourcing 25 µA) 2.50 - - V
Output low voltage (sinking 25 µA) - - 0.05 V
Digital Output (Switch to Ground)
Sink current (do not exceed) - - 250 mA
Voltage limits (high impedance) -10 - 150 V

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Parameter Min Type Max Units

Output Voltage - I/O 01 and I/O 02 (sinking 250 mA) - 1.15 1.35 V
Output Voltage - I/O 03 (sinking 250 mA) - 1.40 1.60 V
Turn-On Delay (I/O 03 only) 140 200 280 ms
I/O 03 only - over current/short circuit protection
Analog Input
Typical input impedance - 1 - MΩ
Minimum measurement voltage - 0 - V
Maximum measurement voltage 2.75 3.0 - V
Resolution (12 bits) - 0.7 - mV
Proportional measurement error - - 1.5 %
INL error - - 2 LSB
Absolute limits -10 - 150 V

[Link] Analog Accuracy

The IDP terminal measures the analog inputs using the GND pin as a reference. As the
GND pin is shared with the power supply, return current can create a voltage drop
between the GND pin and the power supply which in many cases changes the reference
point for the analog voltage.
If analog accuracy is required, as per Figure 12, the power supply cables should be
designed to limit voltage drop. As well, the application should be aware that current is a
function of input voltage and the operating mode (i.e., receive, transmit, sleep)
Figure 12 Analog Accuracy by Limiting Voltage Drop on Return Current

VIN
Power Supply
GND (VGND)
V (ANALOG REF) –
V (ANALOG REF) V (GND) is not equal to
zero due to voltage drop A/D
induced by return current

V (ANALOG) I/O1, 2, 3

Alternatively for accurate analog measurements, the analog reference can be connected
on a separate conductor to GND as per Figure 13. In this case, it is important that the
power supply’s return is fully isolated from the analog reference voltage to ensure return
current does not flow to analog reference.

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Figure 13 Analog Accuracy with Independent Analog Reference

VIN
Power Supply
GND (VGND)

V (ANALOG REF)
No current flows from GND to A/D
V (ANALOG REF)

V (ANALOG) I/O1, 2, 3

3.3 RF Connector
The IDP-800 is optionally available to support a remote antenna. The remote antenna
terminal variant uses an SMA panel connector.
The terminal must only be used with an active SkyWave antenna. Refer to APPENDIX A
for antenna order part numbers.
Table 25 RF Connector
Parameter Value
Antenna Connector SMA female, normal polarity
Maximum Cable Length 8m

3.3.1 Antenna Cut Detection

For remote antenna versions, the terminal can detect when the antenna is disconnected. It
detects the antenna disconnect by monitoring the DC current to the antenna when it is
receiving either a GPS or IsatData Pro signal.

3.4 Pass-Through Mode

The terminal operates in pass-through mode when there is no application firmware
present. A block diagram of pass-through mode is shown in Figure 14. In pass-through
mode, the terminal connects the modem's serial interface to the terminal's RS-232 port.

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Figure 14 Pass-Through Mode Signals

Terminal

Power Supply

GND/VIN (PINS 1, 6)

I/O 01 (PIN 4)
1PPS
I/O 02 (PIN 5)
EVENT_NOTIFICATION
Connector RS-232
Active MODEM_WAKE
RS-232 Rx (PIN 2) UP
SERIAL_RX Modem
Transceiver
RS-232 Tx (PIN 3)
SERIAL_TX

The terminal's I/O lines are configured as per Table 26 when in pass-through mode. The
modem's serial data and the EVENT_NOTIFICATION pins are connected to the
terminal's external connector.
Table 26 Pass-Through Mode Power
I/O Pin State Specification
I/O 01 1 PPS I/O configured as digital output
Connected to 1 PPS from GPS/GLONASS
The 1 PPS output is only present when GPS/GLONASS
has a valid signal
I/O 02 Output Connected to EVENT_NOTIFICATION
I/O 03 Analog Input Do not use
RS-232 RS-232 Disabled if no valid RS-232 level on receiver
Pass-through mode time specifications are given in Table 27.
Table 27 Pass-Through Mode Timing Specifications
Parameter Specification
Baud Rate As per modem configuration
Maximum Jitter on Signals 10 µs
(Modem to External)
Maximum Jitter on Signals 10 µs
(External to Modem)

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Table 28 Pass-Through Mode Power Consumption

Mode of Operation Current
Pass-Through 45 mA @ 12 volts

3.5 Serial Interfaces

3.5.1 RS-232
The RS-232 interface defaults to the following settings: 9600 bits/s, 1 start, 8 data, 1 stop
bit, no parity. The guaranteed minimum baud rate is configurable up to 250 kb/s.
The electrical characteristics of the interface are show in Table 29.
Table 29 RS-232 Electrical Characteristics
Parameter Minimum Typical Maximum Units
Serial Rx Input Voltage Range -25 - 25 V
Serial Rx Input Low Threshold 0.6 - - V
(Vcc 3.4 V)
Serial Rx Input High Threshold - - 2.4 V
(Vcc 3.4 V)
Serial Tx Low Output - - -3.7 V
(loaded with 3 k to ground)
Serial Tx High Output 3.7 - - V
(loaded with 3 k to ground)
ESD Performance
RS-232 pins (Tx, Rx) - ±15 - kV

[Link] Auto RS-232 Power On/Off

The terminal uses the input voltage to turn the RS-232 driver on/off when auto RS-232
mode is selected.
Table 30 Auto RS-232 Power On/Off
Parameter Value
Valid Rx Input Threshold Rx > 2.7 V or Rx < -2.7 V
Invalid Rx -0.3 V < Rx < 0.3 V

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3.6 RF Specifications
3.6.1 Frequency
Table 31 Frequency Specifications
Parameter Value
Receive
Frequency Band 1525 to 1559 MHz
Modulation OQPSK
Symbol Rate 3000 symbols/seconds
Polarization RHCP
Transmit
Frequency Band 1626.5 to 1660.5 MHz
Modulation OQPSK
Symbol Rate 900 symbols/seconds (maximum)
Polarization RHCP

3.6.2 IDP-800 Terminal with Integrated Antenna

Table 32 Terminal with Integrated Antenna RF Specifications
Parameter Value
Maximum EIRP 7 dBW
Elevation Angle 20 degrees
Maximum transmit antenna gain 4.5 dBic

3.6.3 Remote Standard Antenna

Table 33 Remote Standard Antenna RF Specifications
Parameter Value
Maximum EIRP 7 dBW
Elevation Angle 20 degrees
Maximum transmit antenna gain 4.5 dBic

3.6.4 Remote Low Elevation Antenna

Table 34 Remote Low Elevation Antenna RF Specifications
Parameter Value
Maximum EIRP 5 dBW
Elevation Angle -15 degrees
Maximum transmit antenna gain 2.5 dBic

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3.7 GPS/GLONASS
The manufacturer's specifications are given in Table 35. Refer to APPENDIX A for
hardware part numbers.
Table 35 Hardware GPS and GPS/GLONASS Specifications
Parameter Hardware GPS GPS/GLONASS Mode
(Modem HW #4) (Modem HW #5)
GPS GPS GLONASS
Time to First Fix11
Cold Start 27s 29s 30s
Warm Start 27s 28s 25s
Hot Start 1s 1s 1s
Sensitivity
Tracking -159 dBm -162 dBm -158 dBm
Hot Start -156 dBm -156 dBm -156 dBm
Cold Start -147 dBm -148 dBm -140 dBm
Acquisition - - -
Accuracy
Horizontal Position (CEP) 12 2.5 m 2.5/2.0 m 4.0 m
Velocity 0.1 m/s 0.1 m/s 0.1 m/s
Heading 0.5 degrees 0.5 degrees 0.5 degrees

3.7.1 1 PPS Signal

The 1 PPS signal is available from the hardware GPS modem. It is a CMOS/TTL output
and outputs a pulse every second, providing a valid GPS signal is present. If the GPS
signal is blocked, the 1 PPS stops.
By default the GPS is only on when requested by the application or the network. For
constant time updates, the GPS must be on at all times (continuous GPS). Refer to [T204]
for further details.

11
All satellites at -130 dBm
12
CEP, 50%, 24 hours static, -130 dBm

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3.8 Internal Battery

3.8.1 Battery Type
The terminal has been tested and certified with the batteries listed in Table 36. The
specifications in Table 36 have been extracted from the manufacturer's specifications.
CAUTION Use only approved batteries listed in Table 36.

Table 36 Approved Batteries

Rechargeable Batteries Non-Rechargeable
Batteries
Battery Chemistry NiMH13 Li/FeS214
Approved Manufacturer Tenergy Energizer
Part Number 10321 L91
(Ultimate Lithium)
Cell Size AA AA
Number of Cells 12 12
(6 series x 2 parallel)
Charge (capacity) Retention15 80% 99%
Shelf Life Recharge storage batteries 15 years @ 21°C
every four months
Quick Charging 660 mA for 3 hours N/A
Top-off Charge Period 1 hour N/A
Total Charge Period 4 hours N/A
Nominal Cell Voltage 1.2 V 1.5 V
Battery Pack Voltage (nominal) 14.4 V16 9 V6
Nominal Capacity 2000 mAh 5400 mAh

3.8.2 Battery Type Identification

Figure 15 and Figure 16 show the battery labels which appear on the underside of the
terminal. The rechargeable battery has NiMH after the part number and the non-
rechargeable battery has Li/FeS2 after the part number.

13
[Link]
14
[Link]
15
20°C for 6 months
16
Nominal voltage

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Figure 15 Rechargeable (NiMH) Battery Label

Battery Chemistry

Figure 16 Non-Rechargeable (Li/FeS2) Battery Label

Battery Chemistry

3.8.3 Battery Lid Matching

It is important to only install rechargeable batteries in the rechargeable terminals and
non-rechargeable batteries in the non-rechargeable terminals. Figure 17 and Figure 18
show the IDP-800 and battery covers for the non-rechargeable (red dots) and
rechargeable (green dots) terminals. The color dots on the lid and in the battery
compartment must match.
Figure 17 Non-Rechargeable Terminal

Red dots on
battery cover and
battery
compartment

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Figure 18 Rechargeable Terminal

Green dots on
battery cover
and battery
compartment

The label in the terminal battery compartment and on the underside of the terminal
indicates the correct battery chemistry. Do not mix covers between rechargeable and non-
rechargeable terminals as the contact arrangements differ.

3.8.4 Battery Protection

When one or two cells are installed incorrectly in a particular string, the total string
voltage is reduced by N x 2 x Vcell, where N is the number of reversed cells and the
Vcell is the cell's voltage. For example, if one cell has 1.2 V typical and a 6 cell string
has 7.2 V, one reversed cell changes the output to Vo=7.2 - 2 x 1.2 = 4.8 V, and two
reversed cells make Vo=7.2 - 2 x 2 x 1.2 = 2.4 V. This applies to both NiMH and Li/FeS2
batteries.

[Link] Non-Rechargeable (Li/FeS2) Cells

Reverse voltage protection blocking diodes are provided as shown in Figure 20 to protect
the terminal if the batteries are installed with the incorrect polarity. If one cell in one
string is reversed, the terminal powers on normally. The string with the reversed cell has
a lower voltage and so only the good string provides power to the terminal.
Due to the blocking diode associated with the reversed cell string being reversed biased,
the good string does not feed current into the string with the incorrect polarity.
The reversed cell scenario is undetectable by the terminal and in this case does not result
in overheating or rupturing. Battery life is effectively reduced by 50%.
If all the cells are reversed the terminal does not power on.

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Figure 19 Battery Protection Circuit (Li/FeS2)

[Link] Rechargeable (NiMH) Cells

If all the batteries are installed incorrectly (reversed), this causes an internal fuse (F2),
which prevents high current flowing out of the batteries, to open up. In this situation the
terminal would need to be repaired (returned to SkyWave) in order to replace the fuse.
Note that the terminal is still capable of powering on from the external supply in this
situation.
If one cell is installed incorrectly, the terminal starts up as usual and the charger turns on.
The reversed cell increases in temperature and heat damage or rupturing may occur. In
this case all the battery cells should be discarded and replaced with new ones. Reverse
charging is not preventable if cells are reversed.
Each reversed cell drops the effective battery voltage by 2.4 V. Three reversed cells drop
the battery voltage below the allowed minimum and the power controller does not start
the charger or power on the terminal.
Figure 20 Battery Protection Circuit (NiMH)

3.8.5 Charger
The IDP-800 internal charger only supports rechargeable NiMH battery chemistries.
Only use approved NiMH batteries in the IDP-800. The IDP-800 charger operates
independently of the Lua framework. Consequently, charging can occur in any operating
mode.
The charging algorithm is outlined in Figure 21 and described in detail later in this
section.

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Figure 21 Charging Flowchart17

Battery < 11 V External Supply Connected Forced Update Time

External No
Supply > Set
Minimum

Yes

No
Temperature
within Range

Yes

Abort
Charger Cycle
(3 stage process)

Full Charge

Reset Forced
Charger Timer

17
Flowchart applies to firmware 4.x.

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[Link] Charger Stages Initiation

The internal battery cannot be continuously charged. However, it is important to ensure
that the internal battery has a maximum charge when external power is disconnected.
Charging is initiated in the following cases providing the temperature range is valid.
• External power applied
• Forced charger duration
• Low internal battery voltage
Table 37 Charger Initiation Parameters
Parameter Condition Min. Typical Max. Units
Minimum external Minimum voltage required 9 - 32 V
voltage for charging
Forced update time Default is the minimum 20 20 120 days
value. Timer resets after
each charge cycle.
Temperature to start As measured in the battery -10 - 45 °C
charging compartment
Internal battery voltage Charger starts if in correct - - 12 V
temperature range

[Link] Temperature Monitoring

The battery manufacturer specifies a cell voltage range for charging. The IDP-800
charger uses a temperature sensor in the battery compartment to determine the battery
cell temperature. The battery temperature sensor is only available with rechargeable
models. This temperature reading is very different from the modem temperature.
Specifications for the battery temperature sensor are given in Table 38.
Table 38 Battery Temperature Specifications
Parameter Value
Range -55 to +130°C
Accuracy ±2.5°C max (30°C)
±3.5 to ±3.8°C max (-55°C and 130°C)

3.8.6 Charging Stages

The NiMH charger uses three charging current stages to charge the battery. These current
profiles depend on temperature, battery voltage and battery charge status. The current
stages are pre-charge, fast-charge and top-off charge.
• Pre-charge current is the first charging stage. It is used while the NiMH battery
voltage is below 12 V. NiMH batteries require a pre-charge stage as they can be
damaged if fast charge is applied when the battery is fully discharged.
• Fast-charge current is the second charging stage. The charger enters this stage
when the battery voltage is over 12 V. The charger remains in the fast-charge
stage for 4 hours or until the dV/dt threshold is exceeded.
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• Top-off current is the third charging stage. It is active for one hour.
Table 39 lists the specifications for the three charging stages. Note the currents shown are
only applicable to current supplied between the charger and the batteries and do not
include current drawn from the external supply. For external currents during charging see
section 3.2.2.
Table 39 Charging Stage Specifications
Parameter Condition Min. Typ. Max. Units
First Stage: Pre-charge Current
Pre-charge current Pre-charge when battery voltage - 170 - mA
< 12 V
Pre-Charge As measured in the battery -10 - 5018 °C
Temperature Range compartment
Pre Charge Normally the charge goes to fast- - - 16 hour
Maximum Duration charge when the battery voltage
>12V.
However, the charger remains in
pre-charge to charge the battery if
the temperature is < 0°C.
Second Stage: Fast-charge
Fast-charge Current Fast-charge current is a constant - 660 - mA
current
Maximum time for Assuming dV/dt and temperature - 4 - hours
fast-charge is in range
Maximum Assuming temperature is in range - - 59 mV
-dV/dt threshold to and timer not expired
terminate fast-charge
Fast-charge As measured in battery 0 - 5018 °C
temperature range compartment
Third Stage: top-off
Top-off charge Temperature must be in range - 85 - mA
current
Top-off maximum Temperature must be in range 1 hour
duration

3.8.7 Battery Monitoring

Battery voltage is sampled independent of any modes every second when external power
is applied. When external power is removed the battery is sampled at various intervals
depending on the voltage of the battery. For example, with an NiMH battery measuring
15 V the sample period is every 180 seconds and for a battery measuring 12 V the sample

18
As the battery compartment temperature is to measure temperature, the maximum temperature is
reduced from the safety recommendation provided by the battery manufacturer.

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period is every 5 seconds. Each time the battery voltage is measured 16 samples are taken
and the average calculated.

[Link] Battery Voltage

Battery voltage is dependent on a number of factors. Battery voltages vary depending on
load, load duration, recovery time since the last load, remaining battery capacity and
temperature. As the battery is depleted, the effects of load and temperature increase. If
using the battery voltage as an indicator of remaining battery life, the conditions under
which the voltage was measured must be taken into account. For example, the battery
voltage is lower during transmit than during receive. Similarly the voltage is lower when
the batteries are cold than when they are warm and may be lower after a long
transmission relative to a short transmission.

[Link] Long Messages

Long transmissions made while the batteries are weak may cause the voltage to drop to
the point where the terminal enters its battery recovery cycle. If the voltage drops too
low, the terminal shuts down for a period of 16 hours to allow the batteries to rest/recover
before powering back up to resume operation and if necessary, retrying the transmission
that caused it to shut down. Battery life can be maximized by limiting the size of the
message and limiting data transmissions.

3.9 Accelerometer
The IDP-800 has an internal 3D accelerometer to detect motion in any axis. Figure 22
shows the positive axes for the accelerometer.
Figure 22 Accelerometer Axis

The accelerometer is very important for low power terminals when it is critical to save
power while stationary and quickly detect when motion starts. In powered terminals
where low power is not critical, GPS can be polled to detect motion. However, for low
power applications like the IDP-800, frequent GPS fixes can dominate the power budget.
To reduce power budget effects of GPS fixes, an accelerometer can be used to trigger a
GPS fix to detect if motion occurred.

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The accelerometer thresholds to detect motion vary depending on the environment. In

order to avoid, false motion detects, extensive testing is required to ensure that adequate
acceleration magnitude thresholds and time durations are used. Refer to [T202] for
further details about the accelerometer.
Table 40 Accelerometer Specification
Parameter Condition Min. Typical Max. Units
Resolution 2g - 3.91 - mG
Acceleration Range software selectable - ±2 - g
software selectable - ±4 - g
software selectable - ±8 - g
software selectable - ±16 - g
Bandwidth Filtering Selectable via digital 8 - 1000 Hz
interface
Sensitivity 2g - 256 - LSB/g
4g - 128 - LSB/g
8g - 64 - LSB/g
16 g - 32 - LSB/g

3.10 Nonvolatile Storage

The terminal has nonvolatile flash memory that is shared by the terminal firmware and
user services.
Table 41 Nonvolatile Storage
Parameter Value
Nonvolatile On-board Flash Storage 4 MB
Write-Erase Cycles (per operating life) 100 000

3.11 Environmental
Parameter Description
Humidity The terminal meets all its specifications after exposure to 90%
relative humidity at +85°C, per the test methodology of SAE
J1455, section 4.2.3.
Vibration The terminal meets all its specifications during exposure to
random vehicular vibration levels per SAE J1455, section
[Link] and MIL-STD-810G, section 514.6, fig 514.6C-1.
Mechanical Shock The terminal meets all its specifications after exposure to
positive and negative saw tooth shock pulses with peaks of 20G
and durations of 11 ms as specified in MIL-STD-810G, section
516.6, Procedure I, section 2.3.2c, 3/axis/(positive and negative
direction).

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Parameter Description
Altitude The terminal meets all of its specifications after a non-operating
12.2 km altitude test as detailed in SAE J1455, section 4.9.3,
except with an ambient temperature of -40°C.
Thermal Shock The terminal meets all of its specifications after a thermal
shock test as detailed in SAE J1455, section [Link].
Salt Spray The IDP-800 meets all of its specifications after a salt spray test
Atmosphere as detailed in SAE J1455, section [Link].
Immersion The terminal meets all of its specifications after a 6 hour
alternating hot/cold salt water immersion test as detailed in
SAE J1455, section [Link].
The terminal meets all of its specifications after a 30 minute, 1
m depth fresh water immersion test as detailed in IEC 60529,
section 14.2.7.
These immersions were performed without a cable mating with
the circular connector.
Exposure to The terminal meets all of its specifications after a light to
Chemicals and Oils moderate splash test as detailed in SAE J1455 section [Link],
for the following chemicals:
Window Washer Solvent
Gasoline
Diesel Fuel
Fuel Additives
Alcohol
Anti-Freeze Water Mixture
Degreasers
Soap and Detergents
Steam
Waxes
Kerosene
Freon
Spray Paint
Paint Strippers
Ether
Dust Control Agents (magnesium chloride)
Moisture Control Agents (calcium chloride)
Ammonia
Aluminum brightener (acid wash)
Steam Cleaning and The terminal meets all of its specifications after a steam
Pressure Washing cleaning and pressure wash test as detailed in SAE J1455,
section 4.5.3.
Fungus The terminal meets all of its specifications after a fungus test as
detailed in SAE J1455, section 4.6.3.
Dust and Sand The terminal meets all of its specifications after a dust and sand
Bombardment bombardment test as detailed in SAE J1455, section 4.7.3.

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Parameter Description
The terminal meets the acceptance conditions of IEC 60529,
section 13.6.2 after a dust and sand bombardment test as
detailed in IEC 60529, section 13.4.
Drop Test The terminal meets all its specifications after a handling drop
test as specified in SAE J1455, section [Link].

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3.12 Mechanical
All dimensions are shown in millimeters (mm).

3.12.1 Terminal
Figure 23 IDP-800 Top View Enclosure Dimensions
6 x 4.8 (hole size)

133.4

203.2 203.2
4 x 6.4 (slot)
Figure 24 IDP-800 Side View Enclosure Dimensions

6.4
Mounting Foot 432.2
Height
Figure 25 IDP-800 Connector View Enclosure Dimensions

25.4

148.1

Table 42 IDP-800 Terminal and Bracket Mass

Parameter Value
Terminal without batteries ~0.94 kg
Terminal with rechargeable batteries ~1.27 kg
Terminal with non-rechargeable ~1.14 kg
Magnet mount bracket
(brackets, magnets, and fasteners) ~0.50 kg
VHB mount bracket
(brackets and fasteners) ~0.42 kg
Enclosure Material Lexan EXL9330 Resin

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3.12.2 Remote Antenna

Figure 26 Remote Standard and Low Elevation Antenna - Bottom View
2 x 72.4
4 x 5.500
(HOLE)

126.2±0.2

2 x 112.8

35.5±0.2

46.5±0.2 4 x 15.9

Note: Centre antenna cable hole is for bottom connector antenna only.

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Figure 27 Remote Standard Antenna Height Dimensions

25±0.3

Figure 28 Remote Low Elevation Antenna Height Dimensions

76±0.3

Table 43 Antenna Mass and Material

Parameter Value
Remote Standard Antenna
(Side entry with 5 m cable) 360 g
Remote Low Elevation Antenna
(Side entry with 5 m cable) 365 g
Enclosure Material Xenoy 5220U

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4 Installation
The following section contains recommended installation guidelines for the Solution
Provider (SP). These recommendations should be incorporated into installation guidelines
for end users.
CAUTION The installer is responsible for following all safety guidelines
during product installation. Refer to Preface section for details.
The terminal uses very low power during transmission and therefore presents no radiation
hazard during normal use, installation, testing, and troubleshooting.

4.1 Getting Started

Getting the terminals ready for operation requires doing the following:
1. Prepare for the installation (Section 4.2)
2. Determine a suitable mounting location (Section 4.3)
3. Identify the fuse panel location (Section 4.4)
4. Prepare the batteries (Section 4.5)
5. Mount the terminal (Section 4.6)
6. Mount the remote antenna (optional) (Section 4.7)
7. Route the main cable (optional) (Section 4.8)
8. Apply power (Section 4.9)
9. Register the terminal (Section 4.10)

4.2 Prepare for the Installation

Check that you have the items and tools listed below before installing the terminal.

4.2.1 Shipping Box Contents

Unpack the contents of the shipping box(s) and use the list below as a guide to check that
you received the items you ordered.
• IDP-800 terminal
• 12 x rechargeable or non-rechargeable batteries (optional)
• Remote standard or low elevation antenna (optional)
• Mating connector kit with tube of dielectric grease
• Power on/off magnet fob
• Installation Guide
• Optional kits (APPENDIX A)

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4.2.2 Mobile Identification

Each terminal has a unique mobile ID used to register it on the IsatData Pro network.
This is a 15-digit alphanumeric identifier in the format NNNNNNNNSKYXXXX. The
mobile ID is located on the bottom of the terminal and on the battery end, as well as on
the shipping box.
Each remote antenna has its own serial number (Figure 29). This label should be visible
after mounting the antenna.
Figure 29 Mobile ID Location

Mobile ID

1. Record the mobile ID in APPENDIX B for future reference.

Note: Terminals may be activated on the network prior to or after shipping
based on the Purchaser (SP) agreement.
Figure 30 Remote Antenna Serial Number Label Location (standard antenna shown)

Serial Number

4.2.3 Activate the Terminal

In order to send or receive any message you must activate the terminal on the IsatData
Pro network.
1. Log in to [Link] type your user name (registered email) and
password, and then click GO. Contact Customer Support if you do not have access to
this website.
2. Click the Manage Mobiles icon. The Manage Terminals page appears.
3. Click the button next to IsatData Pro Terminal Activations and click NEXT.

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Figure 31 Manage Terminals

4. Select your Gateway Account from the drop-down list.

5. Enter the terminal's mobile ID in the appropriate field and click ADD.
If you have multiple mobile IDs, you can use the UPLOAD FILE option.
6. Verify that at least one contact email address is shown in the Notification section on
the data entry page.
Keep a copy (APPENDIX B) of the terminal's mobile ID along with the server access
ID and password you receive in the activation report email (Figure 32) from
Customer Support. You need these to communicate remotely with the terminal.
7. Click SUBMIT.
Figure 32 Sample Activation Report

Access ID and password required

to securely access your messages
over the Internet

The Mobile ID is the serial number which appears on the

terminal and is used to uniquely identify the terminal when
sending and receiving messages

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4.2.4 Programming the Terminal

If the IDP-800 is not shipped with a customer specified application, the terminal must be
programmed before deployment to ensure it is configured for low power operation. A
number of installation tools are available, including Terminal Installer, to help ensure the
terminal is programmed correctly.
When programming the IDP-800, it is important to use external power to avoid draining
the batteries.

4.2.5 Required Materials

You require the following materials to install a terminal. These materials do not ship with
the terminal.
• Qty 6 - M4 (8-32) 18-8 stainless steel screws (length depends on mounting
surface thickness)
• Qty 6 - M4 (8-32) nuts with 18-8 stainless steel flat and lock washers
• Waterproof sealing tape
• Qty 1 - Custom cable
The Solution Provider should supply the end-user with a custom built cable.

4.2.6 Required Tools

You require the following tools to install a terminal.
• Drill
• 4.5 mm drill bit
• #2 Phillips torque screwdriver
• Socket wrench set

4.3 Determine a Suitable Mounting Location

Before installing the terminal, consider the important guidelines provided below.
CAUTION Most users install the terminals on a vehicle. It is very important
for installers to install the terminals in a safe and secure way to
avoid danger or damage to persons or property.
• Mount the terminal on a flat surface for mobile installations such that the elevation
angle does not change with rotation.
• For fixed installations ensure that the antenna is pointing towards the equator, facing
south if in the Northern Hemisphere and facing north if in the Southern Hemisphere,
and its line of sight to the sky (satellite) is clear of obstructions.
• For a mobile installation, mount the antenna at the highest point on the vehicle or
vessel where it has a clear view of the sky (satellite) in all directions
• Fasten the terminal securely so that it is not loose and does not move easily.

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• Mount the terminal on a rigid, flat, stable surface. If necessary, use a mounting
bracket or other suitable support.
• Mount the terminal so that the top surface is horizontal (flat). Failure to do so may
compromise line of sight between the satellite and the terminal.
• Ensure that the terminal is pointing towards the equator and its line of sight to the sky
(satellite) is clear of obstructions.
• Mount the terminal on a surface that does not get hotter than the maximum operating
temperature. If the surface may get hotter, mount the terminal with a thermal barrier
between it and the mounting surface.
CAUTION Mount the terminal with integrated antenna at least 20 cm away
from humans.
• Do not mount the terminal close to other electrical equipment due to possible radiated
and/or conducted electromagnetic interference.
• Do not mount the terminal close to radar or other communications antennas. Use the
following guidelines:
> 1 m from VHF/UHF antenna
> 3 m from loop antenna
> 4 m from MF/HF antenna
> 5 m from other satellite antennas
Not within a radar beam
• Do not mount the terminal where water may build-up or collect. Choose a location
where water moves away from the terminal.
• Ensure that any paint above the terminal is non-metallic and non-metallic flake, if the
installation is under fiberglass or composite wind fairings.
• Check that the terminal's cable reaches the power source before you drill any
mounting holes.
• Do not mount the terminal close to an exhaust pipe due to the excessive heat and the
potential for the exhaust pipe causing satellite blockage.
• Do not mount the terminal close to air horns or any tractor roof hardware
(e.g., emergency lights) that could interfere with satellite communications.
• Mount the terminal on the driver's side of the vehicle, if possible, when there is a
possibility of strikes by overhanging tree branches.
• Do not install the terminal inside the truck under the roof liner.
• Ensure that vehicle where the terminal is installed provides protection against
overcurrent for the terminal's interconnecting cables.

4.3.1 Review Remote Antenna Mounting Guidelines (Optional)

This section is only required if you are using a remote antenna.
CAUTION The DMR-800/SureLinx antenna is not electrically compatible
with the IDP-800. Both the antenna and the SureLinx or IDP
modem can be damaged if connected to the incorrect antenna.
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CAUTION Mount the remote antenna at least 20 cm away from humans.

CAUTION Cable management and connector strain relief must be

incorporated in the installation. It is highly recommended that
you secure the cable at regular intervals along its length as part
of the installation to prevent cable wear and eliminate strain on
the terminal connector. Damage to the terminal connector
interface or cable may otherwise result leading to hardware
failure.
• Mount the remote antenna where it can reach the terminal and has a clear view of
the sky and satellite. For a mobile installation, this means at the highest point on
the vehicle or vessel where it has a clear view in all directions.
• Do not drill any holes before checking that you have room for the bend radius of
the antenna cable. For reliable operation, do not go below a bend radius of
1.3 cm. Measure the bend radius of the cable as shown in Figure 33.
Figure 33 Remote Antenna Cable Bend Radius

Bend
Radius
(Minimum
1.3 cm)

Correct

• Mount on a surface that is free from dirt, grime, water and grease to avoid
damaging the mounting surface or the vehicle’s paint.
• Mount so that the cable end faces the rear of the vehicle.

4.4 Identify the Fuse Panel Location (optional)

Follow the steps below if applying external power rather than using the batteries.
For installation in a truck, the cable from the terminal connects to the truck's fuse panel
for power. If the terminal is installed on a trailer, an external connection may be made
with the trailer 7-way panel. The availability of power at the 7-way panel may be limited
depending on the specific trailer design. Consult the manufacturer for recommendations.
1. Locate the fuse panel in the truck. The location depends on the type, age, and
model of the truck.
2. Identify an un-switched vehicle power source within the fuse panel for terminal
power.
3. Ensure that the cable you ordered is of sufficient length to reach from the fuse
panel to the final mounting location of the terminal.
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4.5 Prepare the Batteries

The IDP-800 is available specifically configured for rechargeable or non-rechargeable
batteries. If you ordered a terminal with rechargeable batteries the label on the underside
of the terminal shows NiMH, while the non-rechargeable battery label shows Li/FeS2. A
label inside the battery compartment also identifies the cell chemistry.
CAUTION Do not mix battery types or new and used batteries. The label on
the underside of the terminal indicates if the terminal uses
rechargeable (NiMH) or non-rechargeable (Li/FeS2) batteries. A
label inside the battery compartment also identifies the cell
chemistry (Figure 15, Figure 16, Figure 17, and Figure 18).

4.5.1 Install the Batteries

Follow the steps in this section for the initial installation of the batteries. Refer to section
4.12 if replacing batteries.
CAUTION Inserting batteries automatically powers on19 (factory setting) the
terminal which may deplete battery life. Only insert batteries if
deploying the terminal within a reasonable period or performing
application development.
1. Remove the 12 batteries from their packaging.
2. Remove and discard the blue tape around the battery compartment.
3. Lift the battery cover off the terminal. The screws on the battery cover may be
slightly engaged and may need to be turned loose (Figure 34).
Figure 34 Battery Cover Screws

Loosen the
Battery
Cover
Screws

CAUTION Both the battery compartment and the battery cover must
have the same circular colored labels (red for non-
rechargeable and green for rechargeable).
4. Insert the batteries paying close attention to battery orientation (Figure 35).

19
If your terminal has not been factory set to automatically power on, then use the magnet fob to
power on the terminal.

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CAUTION Make sure to install the batteries in the correct orientation

according to their polarity. Polarity is indicated on the battery
cover and on the batteries. Incorrect installation may lead to
battery failure, venting and leakage (Figure 35).
Figure 35 Battery Orientation

Battery
orientation is
indicated on the
battery cover
(positive cell is
highlighted)

5. Test the battery installation following the steps in section 4.5.2.

4.5.2 Test the Battery Installation

When the batteries are installed, it is important to measure the battery voltage using a volt
meter to ensure that all battery cells were installed correctly.

Rechargeable Batteries (NiMH)

1. Verify that the orientation of the batteries is as shown in Figure 36.

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Figure 36 Verify Battery Orientation

2. Make a connection with each voltage meter probe tip and battery contact point as
shown in Figure 37.
3. Verify on the volt meter that the battery (open circuit pack) voltage measures
>14.4V. If the voltage is lower, check the orientation of all batteries and re-test.
Figure 37 Rechargeable Batteries - Voltage Measurement

Curved edge
of the battery
Measure at
cover
these
locations
(one positive
and one
negative)

4. Attach the battery cover following the steps in section 4.5.3 before recharging the
batteries.
Note: Rechargeable batteries must be fully recharged before initial use, even if the
voltage reading is correct.

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Non-Rechargeable Batteries (Li/FeS2)

1. Verify that the orientation of the batteries is as shown in Figure 36.
2. Make a connection with each voltage meter probe tip and battery contact point in
the first string as shown in Figure 38.
Figure 38 Non-Rechargeable Batteries - Voltage Measurement First String

Negative
contact

Curved edge of
the battery
cover

Positive
contact

3. Verify that the battery (open circuit) string measures > 10V. If the voltage is
lower, check the orientation of the batteries and re-test.
4. Make a connection with each voltage meter probe tip and battery contact point in
the second string as shown in Figure 39.

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Figure 39 Non-Rechargeable Batteries - Voltage Measurement Second String

Positive
contact

Curved edge of
the battery
cover

Negative
contact

5. Verify that the battery (open circuit) string measures > 10V. If the voltage is
lower, check the orientation of the batteries and re-test.

4.5.3 Attach the Battery Cover

1. Ensure that the black gasket remains fully seated on the gasket wall (Figure 40) along
the entire perimeter of the battery compartment before reassembling the battery
cover.
CAUTION If the gasket is damaged, it must be replaced. Refer to
APPENDIX A for part number.
Figure 40 Gasket and Gasket Wall

Ensure the gasket

is securely
attached to the
gasket wall

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2. Position the battery cover onto the battery compartment, lining-up the straight edges
(Figure 41).
Figure 41 Battery Cover

Line up the
straight edges

3. Apply firm hand pressure around the outside of the battery cover before tightening
the screws (Figure 42).
Figure 42 Apply Pressure around the Battery Cover

4. Tighten the screws (four places) with a #2 Phillips torque screwdriver. Torque screws
to 0.7 N-m (6 in-lb). The terminal automatically powers on when the batteries are
inserted. When the terminal has power, the LED flashes once, and then flashes again
after 4 seconds and continues to flash for about 12 seconds.
Note: The battery cover should lay flat on the terminal base when properly
assembled and all four screws must be tightened.
CAUTION Do not over torque the battery cover screws as this voids the
warranty.
5. Follow the steps in section 4.5.4 if using rechargeable batteries, before continuing to
install the terminal.

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4.5.4 Recharge the Batteries

Rechargeable batteries must be fully charged (4 hours) prior to initial use. The batteries
can be recharged by connecting either an external power cable (ST100165) or an IDP-
800 AC power adapter cable (ST100164). Ensure battery polarity is correct before
charging.
Follow the steps below to recharge the batteries if using an AC power adapter.
1. Remove the connector cap (Figure 43) on the terminal and align the corresponding
key slot (female) on the IDP-800 AC power adapter (ST100164) to the terminal, and
gently push together (Figure 44).
Remember to keep the connector cap in case you want to reattach it for a water tight
seal in the future.
Figure 43 LED, Target, and Connector Cap
Activation
Magnet
Sensor
(Target)

Connector
Cap

LED

Figure 44 Locking Collar and Key Slot

Locking Collar

Key Slot

2. Tighten the cable connector with hand pressure by rotating the locking collar on the
cable connector clockwise. Do not use a wrench. A tactile click is felt when the collar
is properly engaged.
3. Plug the AC power adapter into a wall outlet.
4. Charge the batteries for at least 4 hours.

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4.5.5 When to Power Off the Terminal

In order to save battery life, remove the power source, including any batteries, from the
terminal:
• When the terminal is out of satellite coverage for an extended period of time
• When the terminal is removed from an asset for storage
• Prior to shipping

4.5.6 How to Power On the Terminal

If the terminal has been powered off it can be powered on in a number of ways:
• By inserting batteries (rechargeable or non-rechargeable)
• By applying external power
• When the power off timer has expired
• By using the activation magnet fob and following the instructions below
1. Hold the activation magnet fob centered on the magnet sensor (Figure 45) for 3
seconds and then remove to power on the terminal. When the terminal has power, the
LED flashes once, and then flashes again after 4 seconds and continues to flash for
about 12 seconds..
Note: It is important that you hold the activation magnet fob on the target for at least
2 seconds and then remove it, in order to power on the terminal. The terminal
remains off if the magnet fob is in place for more than 10 seconds.
Figure 45 Activation Magnet Fob

Activation
Magnet Fob
on
Magnet
Sensor

4.6 Mount the Terminal

The IDP-800 terminal can be installed with or without mounting brackets (APPENDIX
A). Users can also build their own custom bracket (Section 4.6.3).
CAUTION Painting terminals or antennas may interfere with their
performance.

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Note: The Solution Provider is responsible for providing mounting instructions if the
mounting is to be done using tools or configurations that are different from the
ones described in this document.
Note: It is the installer’s responsibility to comply with local electrical codes.
Various options are available to mount the terminal:
• Drill Mount (Section 4.6.2)
• Custom Bracket Mount (Section 4.6.3)
• VHB Mount (APPENDIX E)

4.6.1 Determine Terminal Orientation for Accelerometer Use

If using the accelerometer on the terminal, mount the terminal in one of the
configurations shown below. Refer to [T202] for further details.
Figure 46 Accelerometer and Terminal Orientation

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4.6.2 Drill Mounting Holes

CAUTION These steps are only needed if a mounting bracket is not used.
The mounting surface must be rigid and flat to prevent distorting
the terminal. Damage may otherwise occur.
1. Use the terminal as a template to mark the location of the six mounting holes.
2. Drill the six mounting holes using the drill with the 4.5 mm bit.
3. Secure the terminal to the mounting surface through the drilled holes using the six
M4 (8-32) screws and torque to 1.4 N-m (12 in-lb).
4. Continue with the steps, below, for Apply Dielectric Grease.

4.6.3 Custom Bracket Guidelines

Customers should follow the guidelines below if building their own custom bracket.
• All hardware must be 18-8 stainless steel.
• The bracket should be either CRCQ steel (minimum 18 GA) outdoor powder coat
with phosphate pre-treatment or aluminum (3 mm, 1/8” thick) with #8 stainless
steel PEM studs (16 mm, 5/8” long).
• To prevent unnecessary mechanical stress the bracket must be sufficiently rigid
to maintain flatness or the terminal enclosure seal or structural integrity may be
compromised.
• The bracket design must take into consideration the guidelines outlined in
Section 4.2.4.
• The hardware used to secure the terminal must include a flat washer to spread the
fastener load, and a lock washer to prevent loosening under vibration.
• Apply the recommended torque to the hardware used to secure the terminal.
• The mounting bracket may also be designed to include features (such as a formed
bridge lance) that can be used to secure a cable, using a cable tie for connector
strain relief and cable management. This additional tie down feature is beneficial
where cable tie down points are not located on the asset near the terminal.
When the bracket has been built, attach the terminal to the bracket before continuing with
the next section.

4.7 Mount the Remote Antenna (optional)

Two mounting options are available for the remote antenna: screw mount or silicone
mount.

4.7.1 Screw Mount

If mounting a remote antenna the following tools and materials are required:
• M4 hardware
• Outdoor waterproof adhesive sealant (silicone)

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To mount the antenna, follow the steps below.

1. Find a location for the remote antenna following the guidelines provided in
Section 4.3.1.
2. Use the antenna as a template to mark the location of the mounting holes.
CAUTION Cable management and connector strain relief must be
incorporated in the installation. Secure the cable no more
than 15 cm from the antenna enclosure and at regular
intervals along its length as part of the installation to prevent
cable wear and eliminate strain on the terminal connector.
Damage to the terminal connector interface or cable may
otherwise result leading to hardware failure.
3. Drill the mounting holes using the drill.
4. Apply waterproof sealing compound, such as RTV silicone, around the drill holes so
water does not seep into the asset.
CAUTION Adhesive or silicone cannot block the air vent features shown
in Figure 47.
Figure 47 Air Vent Feature

Do Not Block These Features

5. Secure the antenna in place with self-tapping screws or machine screws and nuts
depending on access to the mounting surface. The remote antenna may also be
mounted using adhesive or a high strength outdoor grade silicone when mounting
holes are not an option in the mounting surface.
6. Connect the SMA connector on the remote antenna cable to the SMA connector on
the terminal and torque to 1.7 N-m (15 in-lb).
Note: The recommended torque specification is approximately finger tight plus a
45 degree rotation using an 8 mm wrench.
CAUTION Cable management and connector strain relief must be
incorporated in the installation. Secure the cable no more
than 15 cm from the enclosure and at regular intervals along
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its length as part of the installation to prevent cable wear and

eliminate strain on the terminal connector. Damage to the
connector interface or cable may otherwise result leading to
hardware failure.
7. Apply heat shrink, included with the terminal, to cover the mated connection with the
terminal. This heat shrink is required to comply with IEC 60945 certification.
Figure 48 Heat Shrink

Heat Shrink

4.7.2 Adhesive Mount

The remote antenna may also be mounted using adhesive or a high strength outdoor grade
silicone when mounting holes are not an option in the mounting surface.
Refer to the adhesive manufacturer's recommendations for application temperature,
application conditions, compatible bonding materials, and minimum curing times when
working with an adhesive. Failure to follow the manufacturer's guidelines could result in
the remote antenna separating from the mounting surface.
CAUTION Adhesive or silicone cannot block the air vent features shown
in Figure 49.
Figure 49 Air Vent Feature

Do Not Block These Features

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[Link] Silicone Side Connector Mount

The following tools and materials are required if mounting a side cabled remote antenna
with silicone.
• Outdoor rated silicone adhesive sealant (GE RTV 108)
• Isopropyl alcohol or an equivalent
To mount the antenna:
1. Find a location for the remote antenna following the guidelines provided in
Section 4.3.1.
2. Clean the asset surface with isopropyl alcohol or an equivalent product that does
not leave a residue.
3. Apply silicone around the hole in the asset and to the bottom surface of the
remote antenna and position onto the assets surface.
4. Apply a generous bead of silicone around the entire perimeter of the remote
antenna enclosure. The two vertical slots shown in Figure 50 are vent features
and must not be filled with silicone.
Figure 50 Apply Silicone to Remote Antenna

Do Not Block These Features

5. Place some weight on the remote antenna while the silicone cures.
6. Connect the SMA connector on the remote antenna cable to the SMA connector
on the terminal and torque to 1.7 N-m (15 in-lb).
Note: The recommended torque specification is approximately finger tight
plus a 45 degree rotation using an 8 mm wrench.
CAUTION Cable management and connector strain relief must be
incorporated in the installation. Secure the cable no more
than 15 cm from the enclosure and at regular intervals
along its length as part of the installation to prevent cable
wear and eliminate strain on the terminal connector.
Damage to the connector interface or cable may otherwise
result leading to hardware failure.

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7. Apply heat shrink, included with the terminal, to cover the mated connection
with the terminal. This heat shrink is required to comply with IEC 60945
certification.
Figure 51 Heat Shrink

Heat Shrink

[Link] Silicone Bottom Connector Mount

The following tools and materials are required if mounting a remote bottom connector
antenna with silicone.
• Outdoor rated silicone adhesive sealant (GE RTV 108)
• 5/16” or 8 mm wrench
• Drill
• 12 to 19 mm drill bit for a straight SMA cable connector
• 29 mm minimum drill bit (hole saw) for right angle SMA cable connector
• Isopropyl alcohol or an equivalent
To mount the antenna:
1. Find a location for the remote antenna following the guidelines provided in
Section 4.3.1.
2. Drill a 12 to 19 mm hole in the asset surface (Figure 52) when using a straight
SMA cable connector. For a right angle SMA cable connector, drill a minimum
hold diameter of 29 mm.
Refer to the note in step 7 if the right angle hole is considered too large.
Figure 52 Drill Mounting Hole

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3. Clean the asset surface with isopropyl alcohol or an equivalent product that does
not leave a residue.
4. Insert the cable through the hole, from inside the asset, and thread the cable
connector onto the antenna. Torque the connector finger tight plus a 45 degree
rotation using an 8 mm wrench.
Figure 53 Attach Cable to Terminal

5. Apply silicone around the hole in the asset and to the bottom surface of the
remote antenna.
Figure 54 Apply Silicone to Hole in Asset

6. Apply heat shrink, included with the terminal, to cover the mated connection
with the terminal. This heat shrink is required to comply with IEC 60945
certification.
7. Lower the remote antenna onto the mounting surface.
The straight SMA cable connector can be lowered straight down onto the
mounting surface.
The right angle SMA cable connector, not shown, must be pivoted down onto the
mounting surface to fit the right angle cable and connector through a larger

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clearance hole. Additional care is required with this installation to ensure the
right angle cable and connector does not smear the silicone around the clearance
hole when attempting to pivot the antenna into position.
8. Apply a generous bead of silicone around the entire perimeter of the remote
antenna enclosure. The two vertical slots shown in Figure 55 are vent features
and must not be filled with silicone.
Note: If the large clearance hole required for the right angle SMA cable
connector is considered too large, there is the option to use a smaller
clearance hole in the mounting surface and install the cable from
inside the asset after the antenna has been adhered with silicone.
In this case, first confirm there is enough room from inside the asset to
thread the SMA cable connector by hand and clearance for the wrench
to apply the final torque.
Also note that the silicone used to mount the antenna must be fully
cured before the cable can be installed from the inside otherwise the
seal and mounting are compromised.
Figure 55 Apply Silicone to Terminal

Do Not Block These Features

9. Place some weight on the remote antenna while the silicone cures.

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4.8 Route the Main Cable (optional)

Consider the following guidelines before routing the cable assembly.
CAUTION Ensure the power cable will not be pinched, kinked or worn
down by any objects or moving parts such as the door hinges. It
is very important to secure the cable at many points along its
path.
CAUTION Prior to working on any cabling, ensure that the terminal is
powered off and will not start while work is in progress.
• Do not route the cable near the engine if routing through the engine compartment.
This location can subject the cable to extreme heat.
• Keep the cable away from hot surfaces such as exhaust pipes as this may damage the
cable.
• Do not run the cable over sharp or jagged edges.
• Place the cable in recesses and channels, whenever possible, to prevent potential
damage or wear by foot traffic.
Note: Remember to leave enough cable slack near the terminal for strain relief so as
not to introduce any additional force on the connector. Secure the cables
during the installation.
Figure 56 Sample Cable Placement in a Vehicle Cab

Run the cable assembly following the steps below.

1. Use tape to temporarily secure the terminal in its final location while you run the
cable.
CAUTION Do not drill any mounting holes at this time.

2. Search for vehicle cab entry points on the side of the vehicle closest to the fuse
panel. This helps to minimize the amount of cable routed along the floor of the
cab.
Where possible route the cable through existing holes in the floor or the firewall
of the engine compartment.
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3. Route the cable starting from the terminal to the fuse panel or battery source.
Note: Tape cable ends to prevent dirt from collecting on the contacts.

4.8.1 Apply Dielectric Grease

1. Cut off one end of the tube of silicone lubricant. Adding the silicone lubricant
(grease) protects the contacts.
2. Insert the tube into the male end of the mating connector (Figure 57).
Figure 57 Apply Silicone Lubricant to Connector

Fill this
cavity

3. Squeeze the lubricant into the mating connecter opening until it is full. Some
lubricant may spill out.
4. Connect the cable connector to the terminal by aligning the corresponding connector
key slot and gently push together.
5. Tighten the cable connector with hand pressure by rotating the locking collar on the
cable connector clockwise. Do not use a wrench. A tactile click is felt when the
collar is properly engaged.
Figure 58 Cable Connector and Locking Collar

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6. Wipe off any extra lubricant around the connector.

7. Wrap the mating connector with waterproof sealing tape if using the connector in
changing weather conditions.

4.8.2 Protect the Cables and Cable Connectors

CAUTION Cable management and connector strain relief must be
incorporated in the installation. It is highly recommended that
you secure the cable at regular intervals along its length as part
of the installation to prevent cable wear and eliminate strain on
the terminal connector. Damage to the terminal connector
interface or cable may contribute to hardware failure.
To protect the terminal's connector interface, follow the guidelines below:
• Apply tape around the cable ends to help in routing the cable.
• Secure the cable such that it does not pull on the connector or strain the terminal
connector.
• Tie the cable down so that the weight of a vibrating cable will not stress or strain
the connection.
• Tie the cable down using cable ties and tie holders (Figure 59) at 300 to 600 mm
intervals along the cable route to prevent chafing, wear, or strain.
• Secure the cable tie holder with a self-tapping screw (Figure 59) for best holder
retention.
Figure 59 Cable Management

Adhesive cable tie

holder. Apply a self-
tapping screw here
for added strength.

4.9 Apply Power

4.9.1 Power on the Battery Terminal
By default the terminal automatically powers on when the batteries or an external power
source are applied.
CAUTION Apply power only after making ground connection.

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CAUTION Before applying power to the terminal, make sure that your
power supply’s rated voltage follows the recommended values.
CAUTION The installer is responsible for complying with local electrical
codes.
Note: If possible wait until the terminal is unblocked (i.e., has a full view of the sky)
before powering up the terminal.
Applying external power automatically powers on the terminal. If the asset is not
outdoors when you apply external power, it powers on the terminal, but the terminal does
not acquire a satellite until it has a clear line of sight.
When connected to an external power source, the terminal gives an indication that it has
power when the LED lights up. Refer to T209 for LED operation information and flash
rates.
1. Locate the main power input and the ground (GND) wires on the cable breakout.
You can connect the terminal ground to ground in the fuse panel or to chassis ground.
To do this, secure the ground wire on the cable assembly to a piece of metal
electrically connected to the vehicle chassis using a sheet metal screw.
2. Ensure that the main power input and ground wires reach the vehicle fuse panel.
If the wires are not long enough, splice similar gauge wire to the main power input
and ground wires so that they reach the fuse panel. Cover any splices with adhesive
lined heat shrink.
3. Connect the ground wire to the grounding point selected in Section 4.4.
4. Connect the main power input wire to the un-switched vehicle power source within
the fuse panel.
5. Loop and secure any excess cabling.
When connected to a power source, the terminal gives an indication that it has power
when the LED lights up. After the start-up sequence completes and network status is
indicated, the LED turns off.
If your application requires extended cable lengths, it is necessary to calculate the cable
voltage drop to determine if the terminal is receiving at least 9 V (with 1 A draw). Large
cable voltage drops may adversely affect terminal operation.
Note: Connect only approved cables to the terminal. Use of other cables will void the
terminal warranty.

4.10 Register the Terminal

Note: The IDP-800 terminal must complete registration to operate.
When you apply power, the terminal goes into satellite search mode to acquire the
IsatData Pro network. This activity may take a few minutes to complete. If you
experience difficulties, refer to Section 5 for troubleshooting suggestions.
1. When the terminal synchronizes itself with the network, it sends a registration
message to the IsatData Pro network.

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Note: The terminal will not register until it has a clear line of sight to the
satellite.
2. The IsatData Pro network records the registration message and forwards the
registration message to the user’s application.
The IsatData Pro network sends an acknowledgement message over the satellite to the
terminal. The terminal is now available to send and receive messages.

4.11 Cleaning Instructions

Wash the terminals with only mild soap or detergent.

4.12 Replacing Lithium Batteries

Below are the steps to replace the terminal's lithium batteries and dispose of them safely.
CAUTION Under no circumstance should you recharge lithium batteries.
Severe personal injury, death, or substantial property damage is
possible.
CAUTION Always follow community disposal guidelines when disposing of
lithium batteries. Refer to the manufacturers' website (product
safety datasheet) for information on proper disposal of lithium
batteries. Do not burn discharged lithium batteries.
Note: Protect the environment — follow policies and procedures established by local
governments and battery manufacturers to safely dispose of batteries.

To Replace the Terminal’s Batteries

CAUTION Use only approved batteries (Section 3.8.1).

1. Use the magnet fob to power off the terminal.

2. Use a torque screwdriver with a #2 Phillips drive, to loosen the four screws located at
the corners of the battery cover until they move around freely. Note: the screws are
integral to the cover. Do not attempt to unscrew them from the cover.
3. Remove the battery cover by prying the cover off at the center of each side
(Figure 60). A flat screwdriver inserted into the slots on the vertical sides and end
face of the terminal may assist cover removal.

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Figure 60 Battery Cover - Sides

4. Remove the old batteries and properly dispose of them.

5. Load a complete new set of approved AA batteries ensuring that the orientation of
each battery matches the corresponding markings molded into the inside of the
battery cover (Figure 35).
CAUTION Make sure to install the batteries in the correct orientation
according to their polarity. Polarity is indicated on the battery
cover and on the batteries. Incorrect installation may lead to
battery failure, venting and leakage (Figure 35).
Figure 61 Battery Orientation

Battery
orientation is
indicated on the
battery cover
(positive cell is
highlighted)

6. Test the battery installation following the steps in section 4.5.2.

CAUTION Do not mix battery types or new and used batteries. Ensure
batteries are inserted with the correct orientation. The label
inside the battery compartment indicates if the terminal uses

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rechargeable (NiMH) or non-rechargeable (Li/FeS2) batteries

(Figure 15, Figure 16, Figure 17, and Figure 18).
7. Replace the gasket (part number: ST100188). Refer to APPENDIX D for gasket
replacement instructions.
8. Position the loaded battery cover onto the terminal, with the curved end of the cover
facing the end of the terminal (Figure 41).
9. Apply firm hand pressure around the outside of the battery cover before tightening
the screws (Figure 42).
10. Use a torque screwdriver with a #2 Phillips drive to tighten the four screws on the
battery cover to 0.7 N-m (6 in-lb).
CAUTION Do not exceed this torque spec as it voids the warranty and
may damage the terminal.
Note: The battery cover should lay flat on the terminal base when properly
assembled.
11. Continue with the steps in section 4.5.4 if using rechargeable batteries.

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5 Troubleshooting the Terminal

The following section contains troubleshooting information for the Solution Provider
(SP) to provide to end users.

5.1 Terminal Does Not Register or Report

On application of external power the terminal should register with the satellite and send a
report.
Note: The terminal must be visible to the satellite to register with the network and
registration normally takes a few minutes.
If the terminal fails to register or report:
• Ensure that the antenna has a clear line of sight to the satellite. The terminal must
operate outdoors and be unobstructed by buildings, forest canopy, and rock cuts.
• Check that no objects or debris are on the antenna (i.e., atop the terminal) and
blocking transmission.
• Verify with your SP that the terminal is assigned to your account and registered
(i.e., that it is sending and receiving) and that the IsatData Pro network is
operating properly.
• Check the condition of the power cable.
• Check that the terminal has been properly powered on by holding the activation
magnet fob centered on the target for at least 2 seconds and then removing to
power on the terminal. When the terminal has power, the LED flashes once, and
then flashes again after 4 seconds and continues to flash for about 12 seconds.
Replace the terminal if the above checks fail to uncover the problem.

5.2 Shipping Terminals Back

If it is necessary to ship the terminal back, follow the RMA process.
Note: Remove all batteries from the terminal prior to returning the terminal. Do not
return the batteries with the shipment as doing so may complicate the shipping
documentation and labeling requirements.
CAUTION Always follow community disposal guidelines when disposing of
lithium batteries. Refer to the manufacturers' website (product
safety datasheet) for information on proper disposal of lithium
batteries. Do not burn discharged lithium batteries.
If you must include the batteries in your shipment, contact Customer Support for specific
shipping and handling instructions.

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APPENDIX A Order Part Numbers

Table 44 Order Part Numbers - Hardware GPS
Terminal Part Number
Batteries Included Batteries Excluded
IDP-800 with integrated standard SM201092-DXX SM201092-CXX
antenna for rechargeable batteries
and hardware GPS
IDP-800 with integrated standard SM201091-DXX SM201091-CXX
antenna for non-rechargeable
batteries and hardware GPS
IDP-800 for rechargeable batteries, SM201146-DXX SM201146-CXX
remote antenna and hardware GPS
IDP-800 for non-rechargeable SM201145-DXX SM201145-CXX
batteries, remote antenna and
hardware GPS

Table 45 Order Part Numbers - GPS/GLONASS

Terminal Part Number
Batteries Included Batteries Excluded
IDP-800 with integrated standard SM201226-DXX SM201226-CXX
antenna for rechargeable batteries
and GPS/GLONASS
IDP-800 with integrated standard SM201225-DXX SM201225-CXX
antenna for non-rechargeable
batteries and GPS/GLONASS
IDP-800 for rechargeable batteries SM201228-DXX SM201228-CXX
with standard remote antenna and
GPS/GLONASS
IDP-800 for non-rechargeable SM201227-DXX SM201227-CXX
batteries with standard remote
antenna and GPS/GLONASS

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Table 46 Order Part Numbers - Antenna

Used with both GPS and GPS/GLONASS modules.
Antenna20 Side Entry Bottom Entry
Remote Standard Antenna ST901065-ASA N/A
(5m cable, SMA)
Remote Standard Antenna ST901061-NSA ST901061-NSB
(no cable, SMA)
Remote Low Elevation Antenna ST901066-ASA N/A
(5m cable, SMA)
Remote Low Elevation Antenna ST901063-NSA ST901063-NSB
(no cable, SMA)
Table 47 Order Part Numbers - Replacement Parts and Kits
Replacement Parts
Replacement Magnet Fob ST100138
Replacement Battery Gasket ST100188
Replacement Battery Compartment Subassembly, Non- ST100189-001
Rechargeable
Replacement Battery Compartment Subassembly, ST100189-002
Rechargeable
Kits
VHB Rail Bracket ST100187
Mating Connector with Solder Cup Kit ST100137
Contact your Account Executive for additional products and ordering codes.

20
Some antennas come in various cable lengths. Contact your Account Executive for additional
details.

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APPENDIX B Activation Information

Server User Name: ________________________________________________________

Password: _______________________________________________________________

Terminal Type/ Mobile ID Location

Description (NNNNNNNNSKYXXXX)

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APPENDIX C Reinstalling or Replacing a Terminal

When removing or replacing a terminal, in most cases the bracket(s) should be left
installed on the asset.

To Replace a Terminal
1. Hold the magnet fob centered on the target (Figure 45) for a minimum of 10 seconds
to turn off the terminal.
2. Remove the terminal by unscrewing the six hex nuts and washers from the bracket
and keep them in a safe place for future use.
3. Install a new terminal on the brackets.
4. Secure the terminal using the washers and hex nuts you removed earlier.
5. Torque the hex nuts to 1.4 N-m (12 in-lb).
Terminals automatically power on when batteries are installed. If necessary, to check that
the terminal has been properly powered on, hold the activation magnet fob centered on
the target for at least 2 seconds and then remove. The LED flashes once, and then flashes
again after 4 seconds and continues to flash for about 12 seconds.

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APPENDIX D Replacing a Battery Gasket

CAUTION Damaged gaskets must be replaced.
(part number: ST100188)
The black battery compartment gasket is accessible with the battery cover removed.
The gasket is secured by hook features on the outside of the gasket wall and matching
loop features on the gasket (Figure 62).
Figure 62 Gasket Hook and Loop Features

Gasket hook and

loop features
(8 places)

To replace the battery gasket follow the steps below.

1. Remove the old gasket by rolling it off the wall at each of the hook and loop
locations.
2. Clean the gasket wall with a lint free cloth to remove any oil and debris.
3. Place the replacement gasket over the gasket wall. The loop features on the
gasket line up with the matching hook features on the gasket wall when the
gasket is properly oriented.
4. Fit the loops over the hooks in eight (8) places (Figure 63).

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Figure 63 Fit Loops over the Hooks

CAUTION Ensure that the black gasket on the terminal remains fully in
place on the gasket wall along the entire perimeter of the battery
compartment.

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APPENDIX E VHB Rail Bracket Installation

This bracket (p/n ST100187) installation is optional.

Installation Guidelines
CAUTION The asset surface must be compliant or be a flat rigid surface.
Rigid, uneven/irregular surfaces are not suited to the VHB rail
bracket mount option.
CAUTION All of the criteria below must be met in order to proceed with the
bracket installation.
• Mount the terminal on a surface within a temperature range of 21° to 38°C.
• The ambient temperature must be at least 15ºC and remain above 15ºC while the
VHB tape cures. The curing time is a function of temperature: at 15ºC, the curing
time is 24 hours, and at 25ºC the curing time is 2 hours.
• The mounting surface must be clean and free of oil, dirt, and debris.
• A painted mounting surface must be free of flaked or blistered paint.
• Both the asset surface and VHB tape must be dry and free of moisture.

Attach the Bracket and Prepare the Surface

You require the following tools and materials to assemble the bracket. These items do not
ship with the kit.
• Terminal
• Torque screwdriver
• Tape measure and tape
Mount the Terminal to the VHB Rail Bracket
1. Place the terminal onto the mounting bracket studs (Figure 64).
2. Attach the lanyard to the center stud, matching the location shown in Figure 64, and
following the order below:
• Flat washer
• Lanyard (not required if using the rivet option below)
• Split washer
• Hex nut

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Figure 64 VHB Rail Bracket and Lanyard

Hex nut
Split washer

Flat washer

Lanyard

Studs
(x6)

VHB tape
(underside)

VHB Bracket

3. Torque hex nut to 1.4 N-m (12 in-lb).

Figure 65 Lanyard Attached to Terminal

4. Secure the terminal in place by assembling the flat washer, split washer, and hex nut
to the remaining five studs.
5. Torque the hex nuts to 1.4 N-m (12 in-lb).
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Figure 66 Assembled Terminal with VHB Rail Bracket and Lanyard

Lanyard

6. Orient the installation so that the length of the bracket is parallel to the length of the
vehicle (Figure 67).
7. Use the tape measure to determine the mounting location for the terminal and then
mark this point with tape.
The terminal should be mounted on the driver's side approximately 1.22 m
(Figure 67) back from the vehicle nose. In most cases it is best to locate the terminal
on the surface between two roof bows. The lanyard dictates the distance from the
driver's side edge of the vehicle, approximately 15 cm.
Note: Do not remove the VHB tape protective backing in this step.

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Figure 67 Installation Location for VHB Rail Bracket and Lanyard

15 cm
Vehicle Nose

Vehicle Rooftop
(driver's side)
1.22 m
minimum

Mark Here

Magnet

Lanyard

Rivet Holes
4 Places

Select a Mount Option

There are two VHB bracket installation options:
• Lanyard strap option
• Rivet option
Required Tools and Materials
You require the following tools and materials for the installation. These items do not ship
with the kit.
• Clean shop cloths
• 50\50 mixture of isopropyl alcohol and water

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• 3M rubber and vinyl spray adhesive 80

• Drill
• Lanyard option only
• Drill bit (appropriate size for the lanyard eyelet)
• Choice of
4 mm diameter aluminum rivet, or
self-tapping screw, or
18-8 stainless steel long bolt with similar flat washer, lock washer, and nut
• Sikaflex -221 (Sikka Corp) or equivalent outdoor adhesive sealant
• Appropriate screw or nut driver if using self-tapping screws
• Rivet option only
• Rivet gun
• Qty 4 x 4 mm blind sealing aluminum rivets
• 4.9 mm drill bit
• Sealing compound

Lanyard Strap Option (optional)

1. Position the terminal in the marked location (Figure 67).
2. Pull the lanyard taut and align the eyelet of the lanyard with a roof edge rivet hole.
If space allows, locate the lanyard's eyelet between two roof edge rivets.
3. Use the lanyard eyelet as a template to mark the location of the eyelet hole.
CAUTION Inspect the backside of the drilling surface to ensure that nothing
will be damaged when the drill bit pierces through the surface.
4. Drill where you marked the eyelet hole using an appropriate sized drill bit.
5. Line up the lanyard’s eyelet with the drilled out hole and fasten with the appropriate
rivet, self-tapping screw, or bolt, washer, and nut combination.
Note: When using a rivet, take care so that the rivet has the proper grip range
for the installation.
6. Seal the eyelet hole with Sikaflex if required.
Attach the VHB Bracket
1. Clean the vehicle's mounting surface thoroughly with a clean shop cloth and a 50\50
mixture of isopropyl alcohol and water. Let dry.
2. Apply the 3M rubber and vinyl spray adhesive 80 to the mounting surface to enhance
the bond between the VHB on the bracket and the mounting surface. This is
especially important if the mounting surface is plastic or painted metal.
3. Wait a few minutes until the mounting location is dry.

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4. Remove the VHB backing tape from the VHB tape attached to the underside of the
brackets.
CAUTION Avoid skin contact with the VHB surface.

5. Pull on the bracket assembly until the lanyard is taut, no slack, in order to locate the
bracket assembly in the proper mounting location.
6. Position the mounting brackets on the mounting surface and apply a minimum force
of 10 kg with both hands firmly and evenly across the entire surface of the VHB
assembly. This ensures a strong bond between the tape and the mounting surface.
Note: The VHB tape must cure for a minimum of 2 hours at 25°C or 24 hours at
15°C. Higher temperatures will shorten the cure time - minimum cure time is
30 minutes at 65°C.

Rivet Option (optional)

The lanyard is not required if supplementary rivets are used. The included lanyard can
therefore be removed from the bracket prior to proceeding.
Mount the Terminal
1. Remove the lanyard from the bracket if you attached it earlier.
2. Position the terminal in the marked location (Figure 67).
3. Clean the vehicle's mounting surface thoroughly with a clean shop cloth and a 50\50
mixture of isopropyl alcohol and water. Let dry.
4. Apply the 3M rubber and vinyl spray adhesive 80 to the mounting surface to enhance
the bond between the VHB on the bracket and the mounting surface. This is
especially important if the mounting surface is plastic or painted metal.
5. Wait a few minutes until the mounting location is dry.
6. Remove the VHB backing tape from the VHB tape attached to the underside of the
brackets.
CAUTION Avoid skin contact with the VHB surface.

7. Position the mounting brackets on the mounting surface and apply a minimum force
of 10 kg with both hands firmly and evenly across the entire surface of the VHB
assembly. This ensures a strong bond between the tape and the mounting surface.
CAUTION The VHB tape must cure for a minimum of 2 hours at 25°C
or 24 hours at 15°C. Higher temperatures will shorten the
cure time - minimum cure time is 30 minutes at 65°C.
8. Drill through the hole provided at each end of the brackets (four places) with
a 4.9 mm drill bit (Figure 68).

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Figure 68 Rivet Hole Locations

Mounting holes

9. Secure 4 mm blind, sealed rivets through each of the four rivet holes.
10. Apply sealing compound to the riveting holes.

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APPENDIX F IDP-800 Blunt Cut Cable

This cable connects the IDP terminal to external power, I/O lines and serial ports. There
are a total of seven pins on this blunt cut cable; two connect the terminal to an RS-232
console serial port, three wires to connect to external I/O lines, and one each for ground
and input voltage. The cable has an over-molded connector, a floating drain wire that is
terminated to ground.
Figure 69 IDP-800 Blunt Cut Cable

Specifications
Parameter Value
Part Number: ST100165 Cable drain wires terminated to ground at IDP terminal
connector (PIN 1 - Figure 70).
Length ST100165-001 5m
ST100165-002 10 m
ST100165-003 15 m
For additional lengths, contact your Account Executive.
Temperature -40°C to +85°C
Ultraviolet rating UV stabilized

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Figure 70 Face View of IDP-800 Blunt Cut Cable Connector

Table 48 IDP-800 Mating Blunt-Cut Cable Color Code

Position Color Wire Gauge Functionality
1 Black 22 AWG Ground
2 Yellow 22 AWG RS-232 Rx
3 Orange 20 AWG RS-232 Tx
4 Brown 20 AWG I/O 01
5 Green 22 AWG I/O 02
6 Red 22 AWG VIN (Vbatt)
7 Blue 22 AWG I/O 03
For wire details, refer to the terminal connector pin out table (Table 16).
Figure 71 Raw Cable Details

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APPENDIX G Cable Assembly Instructions

This section provides the information necessary for the Solution Provider to assemble
IDP power/interface cables for the end-user. The solder cup cable connector kit
(ST100137) ships with the terminal.
The cable assembly procedures in this section are adequate for most installations. For
particularly harsh environments such as maritime installations, use a cable with molded
backfill as per the Blunt Cut cable in APPENDIX F. Please contact Customer Support if
you need recommendations for a cable manufacturer.
Note: It is recommended you choose a raw cable with the following properties:
* The terminal accepts input ranges of 9 to 32 VDC. If your application
requires extended cable lengths, it is necessary to calculate the cable voltage
drop to determine if the terminal is receiving at least 9 V (with 1.7 A draw).
Large cable voltage drops may adversely affect terminal operation.
* Cable jacket and internal conductor installation rated for minimum
temperature range of -40°C to 85°C, and UV compliant where exposure to UV
is expected.
Note: For reliable operation, shield all cables used for power and data connections to
the terminal.
Figure 72 Basic Connector Parts for Soldering Configuration

Connector Sealing Nut

Body

Back Shell and O-ring

Required Tools and Materials

The following tools and materials are required to build the cable using this method:
• A cable21 appropriate for the terminal’s environment
• A knife
• A wire stripper
• Solder
• A fine-tip soldering iron
• A flexible high temperature silicone sealant for outdoor exposure

21
For cables exposed to extreme temperatures and sun, select a cable with a thermal rating of
-40°C to +85°C and a UV resistant jacket.

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Cable Assembly Steps

1. Use a knife to cut and remove the outer jacket of the cable, 12 mm maximum from
the end (Figure 73) and remove any foil shielding.
CAUTION Be careful not to nick the wire insulation.

2. Use a wire stripper to remove 4 mm of insulation from the wires (Figure 73).
Figure 73 Recommended Stripping Length
4 mm
12 mm
max.

3. Twist the ends tightly to prevent stranded wires from fraying.

CAUTION Do not solder dip.

4. Slide the following items over the cable in sequence and as shown in Figure 74: a
sealing nut and a back shell.
Figure 74 Cable with Sealing Nut and a Back Shell

Back Shell

Sealing
Nut
5. Push the red O-ring inside the back side of the back shell (Figure 75).
Figure 75 O-ring

6. Verify the red gasket is present and oriented with the flat face visible in the front side
of the back shell as shown in Figure 76.

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Figure 76 Red Gasket

7. Using a soldering iron and solder, tin the wires and solder them to the connector
solder cups (Figure 77) as per the proper pin-out.
Figure 77 Wires and Solder Cups

8. Ensure the O-ring is in place over the connector body as shown in Figure 78.
Figure 78 O-Ring over Connector Body

9. Use silicone sealant to completely fill the end of the connector and the area between
the wires (Figure 79).
Figure 79 Silicone in the Connector

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10. Slide the back shell up the cable as close as possible to the connector body and fill it
with silicone sealant (Figure 80).
Figure 80 Silicone in the Grommet

11. Assemble the back shell to the connector body and wipe away any excess sealant.
12. Apply sealant over the cable exit area as shown in Figure 81.
Figure 81 Cable Exit Area

13. Assemble the sealing nut over the back shell until the cable grip makes full contact
with the perimeter of the cable jacket (Figure 82). Wipe away any excess sealant.
Figure 82 Assembled Sealing Nut

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APPENDIX H IDP-800 to IDP-680/IDP-690 Adaptor Cable

This cable (ST100143-001) allows an IDP-800 terminal to be installed in place of an
IDP-680/IDP-690 terminal. The cable has seven connections. The RS-485 connections on
the IDP-680/IDP-690 terminal are left unconnected.
Figure 83 IDP-800 to IDP-68/IDP-690 Adaptor Cable

Specifications
Parameter Value
Length 0.3 m
Temperature -40°C to +85°C
Material PVC jacket, 1 mm thick, black
Ultraviolet rating UV stabilized
Figure 84 IDP-800 Mating Connector End Pin-Out

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Figure 85 IDP-680/IDP-690 Connector End Pin-Out

Key Feature

Table 49 Cable Connector Pin-Out

IDP-800 Position IDP-680/IDP-690 Position Wire Gauge
1 3 22 AWG
2 10 24 AWG
3 9 24 AWG
4 7 24 AWG
5 5 24 AWG
6 4 22 AWG
7 6 24 AWG
N/C 1 20 AWG
N/C 2 20 AWG
N/C 8 20 AWG

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Acronyms/Glossary
DC direct current
ESD Electrostatic Discharge
FCC Federal Communications Commission
GND ground
GPS Global Positioning System
I/O input/output
IEC International Electrotechnical Commission
kgf·cm kilogram-force centimeter
LED light-emitting diode
RF radio frequency
RoHS Restriction of Hazardous Substances
R&TTE Radio and Telecommunications Terminal Equipment
Rx receive
SP Solution Provider
Tx transmit

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