SL 30 Field Service Manual
Contents
1. Troubleshooting EQUIPMENT TESTS The tests in the following paragraphs will isolate an SL40 problem to the Com Main board level If the unit fails any of the tests in either the Transmitter or Receiver sections refer to the Disassembly Reassembly procedures on Page 22 for instructions on removing the faulty component The operating specifications listed below are effective for all equipment tests Input voltage 10 Vdc to 40 Vdc reverse polarity protected Input current 300 mA typical 2 A maximum at 13 75 V dc receive 140 mA typical 900 mA at 27 5 Vdc receive 2 1 A typical 3 2 A maximum at 13 75 Vdc transmit 1 0 A typical 1 4 A maximum at 27 5 Vdc transmit NOTE Receiver maximum at full receive audio transmit maximum at 90 modulation at 1000Hz Input power 4 watts typical receive 28 watts typical transmit Internal fuse 7 amp fast blow solder on board Antenna requirements Standard 50Q vertically polarized with VSWR lt 2 5 1 a There are no adjustments for the SL40 b These test procedures should be performed with the SL40 on the service bench to isolate suspected service failures The same tests can be used after replacement of subassemblies to verify proper operation prior to returning the SL40 to service c The HP 8920 AM software HP 11807A will automatically test the SL 40 The specifications are listed in the 51 40 VHF COMM Transceiver Installation Manual d Perform a2. FAA TSO C128 for unintentional transmission stuck mic The Apollo SL40 complies with the FCC requirements specified in CFR 47 Part 87 Aviation Services Subpart D Technical Requirements CFR 47 Part 15 Radio Frequency Devices Subpart B Unintentional Radiators The Apollo SL40 software is designed and tested to RTCA DO 178B level C Note Unauthorized changes or modifications to the SL40 may void the compliance to required regulatory agencies and authorization for continued equipment usage HANDLING CONSIDERATIONS ESD PROTECTION The case on the SL40 is designed to protect the components from mechanical damage and also provides protection from damage due to electrostatic discharge Open the case only when the unit is in an ESD safe work area Observe proper ESD techniques when working on the unit Apollo 5140 Field Maintenance Manual Introduction COMPONENT HANDLING The SL40 contains electrostatic discharge sensitive ESDS components Care must be taken when handling these devices to prevent damage Special precautions for ESD work areas are detailed in ESD Safe Work Area Requirements Page 5 Both you and the work surface must be properly grounded before handling the SL40 components If moving the SL40 components from one area to another they must either be reinstalled in the SL40 case or placed in an anti static bag SHIPPING CONSIDERATIONS All SL40 components must be returned to the factory in anti static p
3. the Test Data Sheet described in Appendix A is to be filled out If all items check out properly the unit may be reinstalled in the aircraft and returned to service SERVICE VERIFICATION Verify that unit has been repaired properly all components have been reinstalled and properly secured and that all functions are set as required Note the date the repairs were completed components replaced technician who performed the repair and any other pertinent details on the Test Data Sheet FUNCTIONAL CHECKOUT After replacement of the faulty component and before reinstalling the SL40 in the aircraft retest the unit to ensure that all functions are operating properly DISPLAY CHECK Perform the display test given on Page 9 Record the test results on the Test Data Log sheet in Appendix A CONTROLS TEST Perform the controls test given on Page 10 Record the test results on the Test Data Log sheet in Appendix A TRANSMITTER TESTS Perform the transmitter tests beginning on Page 13 Record the test results on the Test Data Log sheet in Appendix A RECEIVER TESTS Perform the receiver tests beginning on Page 17 Record the test results on the Test Data Log sheet in Appendix A Apollo 5140 Field Maintenance Manual 25 Checkout Procedures NOTES 26 Apollo 5140 Field Maintenance Manual Appendix A APPENDIX A TEST DATA LOG Once the unit is repaired and the checkout procedure on Page 25has been performed to verify proper operation rein
4. appropriate frequency and key the transmitter and talk into the microphone to check the level FLIGHT TEST CHECK A flight test is recommended as a final installation verification The performance may be verified by contacting a ground station at a range of at least 50nm while maintaining appropriate altitude and over all normal flight attitudes Performance should be checked using low high and mid band frequencies Apollo 5140 Field Maintenance Manual 27 Appendix A CONFIGURATION INFORMATION 5140 VHF COMM 430 6040 2 Mod Serial Antenna DISPLAY AND CONTROLS CHECKOUT OK Display test Controls OK amp Button test MON Button test OK Squelch knob test OK RCL Button test O OK EC Button test OK MEM Button test TRANSMITTER CHECKOUT Transmitter Frequency Error MHz gt 15 PPM O Transmitter Power Watts MHz gt 8 Watts O Transmitter Modulation 100 mV MIC 1 MHz gt 90 Transmitter Modulation 6 50 mV MIC 1 9 0 _ MH 70 Transmitter Modulation 100 mV MIC 2 MHz gt 90 Transmitter Modulation 6 50 mV MIC2 _ MH 70 Transmitter SNR dB MHz gt 35dB Transmitter Audio Distortion MHz lt 10 RECEIVER CHECKOUT O Speaker Audio Distortion lt 5 Receiver Sensitivity Distortion lt 5 Headset Audio Distortion 3926 lt 596 Noise _ dB gt 25dB Ampl lt luv COMMENTS NOTES 28 Apollo SL40
5. component without an RMA Instructions for contacting the factory are given on page 22 PACKAGING FOR SHIPMENT The SL40 circuit boards are subject to both mechanical and electrical damage when improperly handled These components must be packaged for shipment in anti static bags to protect against electrostatic damage and a sturdy protective box to prevent mechanical damage during shipment Ideally the component to be returned should be packaged in the same shipping material that the replacement component is shipped in CONTACTING THE FACTORY FOR ASSISTANCE If the Apollo SL40 unit fails to operate despite troubleshooting efforts contact the 1 Morrow factory for assistance II Morrow Inc 2345 Turner Rd SE Salem Oregon 97302 USA Apollo 5140 Field Maintenance Manual 22 Troubleshooting Phone 503 581 8101 or 1 800 525 6726 Be prepared with the following information about the installation e Installation configuration accessories antenna Model number part number with mod levels and serial number Software versions Description of problem Efforts made to isolate the problem other installed avionics Apollo 5140 Field Maintenance Manual 23 Troubleshooting NOTES 24 Apollo 5140 Field Maintenance Manual Checkout Procedures SECTION 3 CHECKOUT PROCEDURES GENERAL This Section provides procedures for final verification and checkout of the SL40 prior to returning the unit to service During the checkout
6. in evaluating the aircraft communication environment Signal Strength Display RFLVL and Audio Noise Level Display NOISE Additionally there are several adjustments which if improperly set can give the appearance of a malfunctioning radio If the system functions fail to pinpoint or correct a Comm problem remove the SL40 from the aircraft and refer to the Equipment Test procedures on Page 12 for bench testing A built in Display test function allows isolation of Com Display board malfunctions with the SL40 mounted in the aircraft If a problem is isolated to the SL40 Com Display board or Com Main board refer to the Disassembly procedures on Page 20 for instructions on removing and replacing the malfunctioning component Apollo 5140 Field Maintenance Manual 5 Troubleshooting SYSTEM FUNCTIONS The following functions are available in the normal operating mode to assist in isolating problems software version display signal strength display audio noise level display headphone level display and adjustment intercom squelch threshold display and adjustment intercom audio level display and adjustment sidetone audio level display and adjustment base station lockout mode display and adjustment The system functions are enabled by pressing the MON button for three seconds The LED above the MON button will turn off Rotate the LARGE knob to select the function The software version page will be the initial display The front panel but
7. non zero value gives a fixed headphone audio level HphLv 000 Full transceiver functions are operational during this function including transmit Note The headphone level is an 8 bit value with a range of 0 to 255 INTERCOM SQUELCH THRESHOLD DISPLAY AND ADJUSTMENT This function is used to display and adjust the intercom squelch threshold level Turning the small knob changes the threshold IcmSq 200 Full transceiver functions are operational during this function including transmit Note The intercom squelch threshold level is an 8 bit value with a range of 0 to 255 INTERCOM AUDIO LEVEL DISPLAY AND ADJUSTMENT This function is used to display and adjust the intercom audio level Turning the small knob changes the value Setting the value to 0 slaves the intercom level to the volume control knob Setting to a non zero value gives a fixed intercom audio level IcmLv 000 Full transceiver functions are operational during this function including transmit Note intercom level is an 8 bit value with a range of 0 to 255 SIDETONE LEVEL DISPLAY AND ADJUSTMENT This function is used to display and adjust the sidetone audio level Turning the small knob changes the value Setting the value to 0 slaves the sidetone audio level to the volume control knob Setting to a non zero value gives a fixed sidetone audio level SidLv 000 Apollo 5140 Field Maintenance Manual 7 Troubleshooting Full transceiver functions are operationa
8. power output with no MIC audio input 14 Apollo 5140 Field Maintenance Manual Troubleshooting NOTE Set the DC supply voltage to 13 75 volts 0 75 volts prior to performance evaluating the transmitter Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 4 as guides Press PRESET Press TX function Using the CURSOR control knob or the USER keys set AUTO MANUAL MANUAL TUNE Freq 127 5 MHz See NOTE below TX PWR 0 RF IN ANT RF IN AF ANAL IN AM Demod De EMPHASIS off Detector PK 2 AF GEN Freq 1 kHz AF GEN LVL off NOTE Where interference may be a problem use any unused channel for both the SLAO and the HP 8920 as long as both are on the same frequency A frequency close to center of operating range is preferred 2 Set the SLAO as listed below While viewing the frequency display use the large and small knob on the right side of the SLAO to select 127 5 MHz Toggle this frequency into the Active channel Press the PTT button on the test panel EXPECTED RESULTS TX PWR 8 watts 3 UN key the transmitter TRANSMITTER MODULATION Transmitter modulation is measured using the HP8920 This is accomplished by presetting the SL40 to the same channel as the HP8920 inputting a 1000 Hz tone at 50 to 100 mV at MIC 1 and or MIC 2 and reading the transmitter percentage of modulation from th
9. specifications define expected receiver performance Class D Frequency range 118 000 to 136 975 MHz 760 channels Sensitivity 2uV hard for 6dB S N N with 30 modulation at 1000Hz Selectivity lt 6dB variation at 7kHz gt 60dB at 22kHz Speaker audio output level 12 watts into 4Q load 8 watts into 80 load Headphone audio output level 280mW into 100Q load 120 mW into a 500Q load Distortion lt 5 at rated audio output AGC characteristics lt 3dB variation in audio output from 5 uV to 100mV input 15 to 90 modulation Squelch control Automatic squelch with manual override SPEAKER AUDIO TEST The speaker audio level is measured using the HP8920 This is accomplished by connecting the speaker audio to the Audio in high of the HP8920 By adjusting volume control to the desired level 12W and measuring the audio power in watts Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 5 as guides Press PRESET Press RX function Using the CURSOR control knob or the USER keys set AUTO MANUAL MANUAL RF GEN Freq 127 50 MHz AF GEN Freq 1 kHz Amplitude 10 000 u volts RF OUTPUT RF OUTPUT AF Freq 1000 85 Ext Load 4 ohms AC LEVEL units to Watts 2 Connect the speaker load to the HP8920 audio in Turn the SL40 volume control to show an output level of 12 watts on the HP8920 Record the Speaker 1000 Hz Distortion at 12 watts Value should be lt 5 Set the distortion level to Reference 3 Connect the hea
10. ANCE SECTION 3 CHECKOUT PROCEDURES CERERA kaai debere tUe reda dude doe d aen cd SERVICE FUNCTIONAL CHECKOUT eene DISPLAY CHECK CONTROLS TEST TRANSMITTER TESTS RECEIVER TESTS APPENDIX A TEST DATA LOG POST INSTALLATION CHECKOUT SIDETONE LEVEL ADJUSTMENT FLIGHT TEST CHECK 775 5 LIST OF TABLES TABLE 1 REPLACEABLE COMPONENTS LIST OF ILLUSTRATIONS FIGURE 1 SLAO FRONT PANEL FIGURE 2 TEST SETUP DIAGRAM FIGURE 3 EQUIPMENT CONNECTION FIGURE 4 TRANSMITTER TEST SETUP FIGURE 5 RECEIVER TEST SETUP FIGURE 6 COM MAIN BOARD OUTLINE Introduction SECTION 1 INTRODUCTION ABOUT THIS MANUAL This manual provides performance checkout instructions troubleshooting instructions to the board level disassembly and reassembly procedures and test procedures to verify that the unit is once again operational It is intended for use by persons certified by the Federal Aviation Administration FAA to repair aircraft communication devices Section 1 Provides an introduction to the 51 40 unit details handling and shipping considerations for the components and lists required tools and test equipment Section 2 Includes all troubleshooting procedures test setups disassembly reassembly and identifies replaceable components Section 3 Includes ch
11. Apollo Model SL40 VHF comm Transceiver Field Maintenance Manual VISIONARY THINKING TODAY April 1997 Draft 3 560 1014 00 1997 by II Morrow Inc rights reserved Printed in the USA No part of this document may be transmitted reproduced or copied in any form or by any means without the prior written consent of II Morrow Inc Due to II Morrow s commitment to constantly improve the quality and performance of our products information contained in this document is subject to change without notice II Morrow and Apollo are registered trademarks of II Morrow Inc II Morrow Inc 2345 Turner Rd SE PO Box 13549 Salem OR 97302 Salem OR 97309 USA Phone 503 581 8101 1 800 525 6726 In Canada 1 800 654 3415 FAX 503 364 2138 HISTORY OF REVISIONS m ORDERING INFORMATION To receive additional copies of this publication order part 560 1014 Apollo SL40 VHF COMM Transceiver Field Maintenance Manual REFERENCE PUBLICATIONS Following are other publications referenced in this guide IPC 610A Acceptability of Electronic Assemblies 560 0956 Apollo Model SL40 VHF COMM Transceiver Installation Manual NOTES Table of Contents TABLE OF CONTENTS SECTION 1 INTRODUCTIONN 1 ABOUT THIS 0000 APOLLO 51 40 DESCRIPTION FEATURES REGULATORY COMPLIANCE ccsess
12. Field Maintenance Manual M oO R Ou Y T HI NK IN G T O DA Y
13. TX PWR 0 RE ANT RF IN AF ANAL IN AM Demod De EMPHASIS off Detector PK 2 AF GEN Freq 1 kHz Set AF GEN LVL to read 85 modulation Set AF meter to SNR 16 Apollo 5140 Field Maintenance Manual Troubleshooting 2 Set the SL40 as listed below While viewing the frequency display use the large and small knob on the right side of the SL40 to select 127 5 MHz Toggle this frequency into the Active channel Press the PTT button on the test panel 3 Key the transmitter EXPECTED RESULTS SNR 235 dB 4 UN key the transmitter TRANSMITTER AUDIO DISTORTION Transmitter audio distortion is measured using the HP8920 This is accomplished by presetting the SL40 to the same channel as the HP8920 Adjust the amplitude of a 1000 Hz tone input to MIC 1 and or MIC 2 to obtain 85 modulation Then select the audio distortion function on the HP8920 Communications Test Set Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 4 as guides Press PRESET Press TX function Using the CURSOR control knob or the USER keys set AUTO MANUAL MANUAL TUNE Freq 127 5 MHz TX PWR 0 RE ANT RF IN AF ANAL IN AM Demod De EMPHASIS off Detector PK 2 AF GEN Freq 1 kHz Set AF GEN LVL to read 85 modulation Set AF meter to DISTN 2 Key the transmitter EXPECTED RESULTS DISTN lt 10 3 UN key the transmitter Apollo 5140 Field Maintenance Manual 17 Troubleshooting RECEIVER RECEIVER PERFORMANCE The following
14. accomplished by presetting the SL40 to the same channel as the HP8920 and reading the frequency error from the HP8920 Communications Test Set NOTE Set the DC supply voltage to 13 75 volts 0 75 volts prior to performance evaluating the transmitter Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 4 as guides Press PRESET Press TX function Apollo 5140 Field Maintenance Manual 13 Troubleshooting Figure 4 Transmitter Test Setup 2 Using the CURSOR control knob or the USER keys set AUTO MANUAL MANUAL TUNE Freq 127 5 MHz See NOTE below TX PWR 0 RF IN ANT RF IN AF ANAL IN AM Demod De EMPHASIS off Detector PK 2 AF GEN Freq 1 kHz AF GEN LVL off NOTE Where interference may be a problem use any unused channel for both the SLAO and the HP 8920 as long as both are on the same frequency A frequency close to center of operating range is preferred 3 Set the SL40 as listed below While viewing the frequency display use the Large and Small knobs on the right side of the SLAO to select 127 5 MHz Toggle this frequency into the Active channel Press the PTT button on the test panel EXPECTED RESULTS TX Freq Error 0 15 PPM 4 UN key the transmitter TRANSMITTER POWER MEASUREMENT Transmitter power is measured using the HP8920 This is accomplished by presetting the SL40 to the same channel as the HP8920 and reading the transmitter
15. ackaging equivalent to that used to ship the components from the factory Save the packaging from the replacement components to use when returning the failed component Packaging instructions are provided on Page 22 If you have questions regarding shipment of the SL40 components contact the Morrow Service Department Information on how to contact the factory is provided on Page 22 OTHER TOOLS AND EQUIPMENT The following tools and test equipment or equivalent are required to properly evaluate and test the SL40 All test equipment must be calibrated before performing the test procedures in this manual TOOLS A 3 32 hex tool is required to remove the SL40 from the mounting frame in the aircraft A 2 Phillips screwdriver is required for disassembly TEST EQUIPMENT a Power Supply HP6433B DC Power Supply 0 36 V 0 10 or equivalent b RF Signal Generator HP8920 RF Communications Test Set or equivalent c Multimeter FLUKE 8010A Digital Multimeter or equivalent d Test interface Refer to Figure 2 for the Test Interface schematic and SL 40 transceiver setup Apollo 5140 Field Maintenance Manual Introduction NOTES 4 Apollo 5140 Field Maintenance Manual Troubleshooting SECTION 2 TROUBLESHOOTING This section provides information to assist in isolating problems with the SL40 Where required detailed drawings of test setups are provided The specified test equipment is a recommendation based on the equipment used to tes
16. bleshooting UNIT DISASSEMBLY REASSEMBLY DISASSEMBLY Perform the procedures in the following paragraphs to disassemble the SL40 All disassembly must be performed in an ESD safe work area see guidelines on Page 5 using ESD safe working techniques Com Main Board Removal 1 Place the SL40 on a properly grounded work surface 2 Using a 2 Phillips head screwdriver remove the nine 4 40x3 16 flat head screws securing the cover to the chassis 3 Lift the back end of the cover and slide it towards the rear of the chassis until it is clear of tab on the display bezel then remove the cover 4 Disconnect the ribbon cable connector from J603 on the Com Main board 5 Using a 2 Phillips head screwdriver remove the ten 4 40x1 4 panhead screws and lockwashers securing the Com Main board to the chassis 6 Using a 2 Phillips head screwdriver remove the two 4 40x1 4 flathead screws securing the 15 pin d sub connector to the back of the chassis 7 Using a 9 16 deep well socket remove the jam nut and internally toothed lockwasher securing the BNC connector to the back of the chassis 8 With the board positioned tightly against the back of the chassis tilt up the front of the board until it is clear of the bezel then slide the board forward to remove it from the chassis NOTE There is a small notch in the upper right corner of the Com Main board See Figure 6 that allows the board to just clear the tab on the display beze
17. dset load to the HP8920 audio in Turn SL40 volume control to show an output level of 280 m watts on the HP8920 Record the Headset 1000 Hz Distortion at 280 m watts Value should be lt 5 Set the distortion level to Reference 18 Apollo 5140 Field Maintenance Manual Troubleshooting Figure 5 Receiver Test Setup RECEIVER SENSITIVITY The speaker audio level is measured using the HP8920 Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 5 as guides Press PRESET Press RX function Using the CURSOR control knob or the USER keys set RF GEN Freq 118 00 MHz Amplitude 1 000 u volts RF OUTPUT OUTPUT AF Freq 1 000 85 Ext Load 4 ohms AC LEVEL w 2 Connect speaker load to the HP8920 audio in Set SINAD low level to 4 dB LO 4 Turn SL40 volume control until AC LEVEL on 1128920 reads 12 watts 3 The distortion level on the 1128920 should be gt 5 4 Reduce the AF Freq modulation level on the HP8920 to 30 The distortion level on the HP8920 should be lt 5 and the noise level should be gt 25 dB 5 Disable the squelch by pulling out on the volume knob Reduce the signal generator amplitude until the HP8920 displays a 6 dB SINAD value S N N The amplitude level should be lt lu volt Apollo SL40 Field Maintenance Manual 19 Trou
18. e HP8920 Communications Test Set Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 4 as guides Press PRESET Press TX function Using the CURSOR control knob or the USER key s set AUTO MANUAL MANUAL Apollo 5140 Field Maintenance Manual 15 127 5 MHz 0 RF IN AM Demod off PK 2 1 kHz 100 mV and to on Troubleshooting TUNE Freq TX PWR RE IN ANT AF ANAL IN De EMPHASIS Detector AF GEN Freq Set AF GEN LVL 2 Set the SL40 as listed below While viewing the frequency display use the large and small knob on the right side of the SL40 to select 127 5 MHz Toggle this frequency into the Active channel Press the PTT button on the test panel EXPECTED RESULTS modulation gt 90 Set AF GEN LVL 50mV EXPECTED RESULTS modulation gt 70 3 UN key the transmitter 4 Repeat Steps 1 through 3 for the other MIC jack TRANSMITTER SNR SIGNAL TO NOISE RATIO SNR is measured using the HP8920 This is accomplished by presetting the 51 40 to the same channel as the HP8920 Adjust the amplitude of a 1000 Hz tone input to MIC 1 and or MIC 2 to obtain 85 modulation Select the SNR function and the HP8920 Communications Test Set will perform this test automatically Procedure 1 Set the HP 8920 as listed below Use Figure 3 and Figure 4 as guides Press PRESET Press TX function Using the CURSOR control knob or the USER keys set AUTO MANUAL MANUAL TUNE Freq 127 5 MHz See NOTE below
19. eckout procedures to ensure that repairs have been properly completed and unit is fully serviceable Appendix A Includes post repair test data log sheets APOLLO SL40 DESCRIPTION The Apollo 5140 is a 760 channel VHF Comm transceiver It is one member of the Apollo slimline series which includes SL40 Comm the 51 50 GPS and the 51 60 GPS Comm FEATURES The features of the SL40 Comm include 760 channels Frequency range of 118 000 to 136 975 MHz Active and standby frequency display 16 character high intensity alphanumeric LED display Automatic display intensity Back lit buttons Transmit status indicator Frequency memory and recall functions from remote source eight last used eight user stored Weather channels Frequency monitor function Built in intercom function Stuck mic time out Two microphone inputs Internal non volatile memory no battery required Full range input supply voltage 12 watt audio amplifier Apollo 5140 Field Maintenance Manual 1 Introduction Transmit Standby Standby Large Outer Small Inner Active Annunciator Symbol Frequency Knob Knob Frequency Photocell J a O 4 S K MN N Power Volume Squelch Flip Flop Emergency Frequency Recall Frequency Channel Monitor Memory Store Memory Figure 1 SL40 Front Panel REGULATORY COMPLIANCE The Apollo 51 40 is designed and tested to meet the following TSOs FAA TSO C37d for transmit FAA TSO C38d for receive
20. essed and squelch knob pulled out CONTROLS EC EC button pressed CONTROLS MON MON button pressed CONTROLS RCL RCL button pressed CONTROLS MEM MEM button pressed When the SMALL knob is turned the magnitude is displayed 000 to 255 All LEDs are turned off CONTROLS 045 The LARGE knob is not tested in this function It is tested by default by selecting the various test functions TEST SETUP A schematic of the SL40 transceiver test setup is shown in Figure 2 Figure 3 is a graphic presentation of the recommended equipment connected for test 10 Apollo 5140 Field Maintenance Manual Troubleshooting SL40 REAR CONNECTOR 4 4 BOWER 5 AMP FUSE 222222 LI HP 6433B 9 GROUND POWER SUPPLY Key out 2 n M Key out 1 Key out 2 ZR Ne PTT SW 4 dors wy Key out 1 ON y HP 8920 MIC ACC INTERCOM lt gt CONNECTOR INTERCOM SLECTOR SWITCH FE 14 HEADPHONE HP8920 AUDIO IN 8 100 OHM HEADPHONE LOAD 10RXD 11SIGNAL GND HP8920 AUDIO IN N 6 SPEAKER 5 SPEAKER 4 OHM SPEAKER 13 AUDIOGROUND SPEAKER MUTE SWITCH 2 8 MIC1 1 HP 8920 AUDIO OUT 7 MIC GROUN 15 2 7 HP 8920 AUDIO OUT 13 GND j ANTENNA 5 HP 8920RF INPUT Figure 2 Test Setup Diagram fe ed Anisa Key Mic Andie In Speaker or Audio Bah Linder Test Figure 3 Equipment Connection Apollo 5140 Field Maintenance Manual 11
21. his frequency to the active channel Press and hold the MON button for about 3 seconds to reach the System Function Use 8 Apollo 5140 Field Maintenance Manual Troubleshooting the large knob to select the NOISE function and view the receive noise level of the selected frequency The value will change constantly and has a range between 0 and 255 and an RFLVL in the mid teens 14 to 17 On the service bench with the antenna port of the SL40 dummy loaded NOISE should be between 100 and 125 If the SL40 is connected to the aircraft antenna and there is no carrier on the channel expect the reading to be the same or slightly lower To confirm that there is no carrier on the monitored channel pull the squelch knob and listen TEST MODE OPERATION The test mode allows the SL40 display and controls to be tested with the unit still mounted in the aircraft The test mode is also used to access certain test and calibration functions used during manufacture and at the service center Do not change or adjust any functions accessed in the test mode unless specific instructions are provided in this manual If the SL40 fails either the Display or Controls test remove the unit from the aircraft and refer to the Disassembly procedures on Page 20 for instructions on removing the Com Display board TEST MODE ACCESS Enable the built in test mode by pressing the lt gt flip flop RCL buttons while switching the unit on GENERAL OPERATION In test
22. l during this function including transmit Note sidetone level is an 8 bit value with a range of 0 to 255 BASE STATION LOCKOUT MODE DISPLAY AND ADJUSTMENT This function is used to display and adjust the lockout mode Improperly set the lockout can disable various Comm functions giving the appearance of a malfunctioning unit Turning the small knob changes the mode The modes are summarized as follows Locks 000 e Mode 0 Normal pilot mode No disabled functions e Mode 1 amp 3 Toggle Lock Only the Flip Flop button is disabled Fixed Primary frequency Variable Standby frequency Frequencies cannot be swapped e Mode 2 amp 6 Primary Frequency Protected Fixed Primary frequency Variable Standby frequency Frequencies can be swapped Primary is not modifiable when it is the standby freq displayed as Mode 6 Mode 4 Fixed Two Channel radio Both frequencies are fixed Frequencies CAN be swapped Mode 5 amp 7 Toggle Lock w fixed standby frequency Both frequencies are fixed Frequencies CANNOT be swapped Note that it is possible to put the unit into mode 8 but on re entry to the system functions it will be show as mode 0 Full transceiver functions are operational during this function including transmit Note The lockout mode has a range of 000 to 008 While viewing the frequency display use the large and small knobs on the right side of the SLAO to select an unused local channel Toggle t
23. l when the board is properly positioned If more that a very slight forward pressure on the bezel is required to remove the Com Main board check the position of the board in the chassis and ensure that the notch is aligned with the tab on the bezel COM MAIN BOARD Figure 6 Com Main Board Outline aera eye S p sod s aod 5 E SL SIE 355 S G ceed bie cee ana is k Gk NUS OS 20 Apollo 5140 Field Maintenance Manual Troubleshooting Com Display Board Removal 1 Place the SL40 on a properly grounded work surface 2 Using a 2 Phillips head screwdriver remove the nine 4 40x3 16 flat head screws securing the cover to the chassis 3 Lift the back end of the cover and slide it towards the rear of the chassis until it is clear of tab on the display bezel then remove the cover 4 Disconnect the ribbon cable connector from 11 on the Com Display board 5 Using a 2 Phillips head screwdriver remove the three 4 40x1 4 flat head screws one on each side and one on the bottom that secure the display bezel to the chassis and remove the bezel REASSEMBLY Perform the procedures in the following paragraphs to reassemble the SL40 All reassembly must be performed in an ESD safe work area see guidelines on Page 5 using ESD safe working techniques Com Main Board Replacement 1 Tilt
24. ll tests at normal room temperature 68 to 72 F e Complete the transmitter frequency test before performance evaluating the receiver NOTE All RF voltages are HARD Micro volts Hard micro volts indicates use of a 6 dB pad between the signal generator and the receiver When using the HP 8920 HARD should be set in the test equipment configuration MENU 12 Apollo SL40 Field Maintenance Manual Troubleshooting TRANSMITTER TRANSMITTER PERFORMANCE The following specifications define expected transmitter performance Class 4 Output Power 8 watts minimum carrier at 12 VDC input 6 watts minimum carrier at 10 VDC input The transmit is lock out below 9 VDC input Frequency range 118 000 to 136 975 MHz 750 channels Frequency tolerance 15 PPM from 20 C to 70 C Microphone input Two inputs standard carbon or dynamic MIC with integrated preamp providing minimum 70 mV rms into 1000Q load Modulation capability 85 with 100 mV to 1000 mV rms microphone input at 1000 Hz Audio frequency distortion lt 10 at 85 modulation at 350 to 2500 Hz Audio frequency response lt 4dB variation with 350 to 2500 Hz 85 modulation Carrier noise gt 35dB down Sidetone output up to 280 mW into 1000 120 mW into 5000 Duty cycle 100 Stuck Mic time out 35 seconds reverts to receive Transmit key Input pull low to enable transmitter TRANSMITTER FREQUENCY ERROR Transmitter Frequency error is measured using the HP 8920 This is
25. mode operation the LARGE knob is used to select the different test functions the SMALL knob is used to select additional pages for each test function In general the only test functions that will be used at the Field Maintenance level are the Display test and the Controls test Do not modify any setting displayed while in the test mode TEST MODE PAGE The Test Mode Page is the first page displayed in the test mode TEST MODE When this page is displayed pressing the MEM button will return the COM to normal mode operation DISPLAY TEST FUNCTION This function is used to test the display and LED indicators DISPLAY TEST Press the MEM button to execute the display test The display will sequence through the test by turning on the first four characters the 2nd four the 3rd four and then the last four characters Once the sequence is complete DISPLAY TEST will be displayed Apollo 5140 Field Maintenance Manual 9 Troubleshooting Note This function will not turn on all 35 dots on all 16 characters at the same time This would cause excessive current CONTROLS TEST FUNCTION The controls test function is used to test the control inputs from the front panel As each button is pressed the display indicates the button and the LED is turned on over the corresponding button SQ displays when the squelch knob is pulled out CONTROLS lt gt gt lt button pressed CONTROLS so lt gt E H lt gt button pr
26. nd secure the bezel in position using three 4 40 1 4 flat head screws one on each side and on the bottom 2 Reconnect the ribbon cable from the Com Main board to 11 on the Com Display board Apollo 5140 Field Maintenance Manual 21 Troubleshooting 3 Tilt the SL40 cover so the front edge slides under the tab on the display bezel and position the cover so the screw holes are aligned with the PEM nuts Secure the cover with nine 4 40x3 16 flat head screws REPLACEABLE COMPONENTS The SL40 field replaceable components are listed by 11 Morrow part number in Table 1 Replacement policy and information on proper packaging of the SL40 components for shipment is given in subsequent paragraphs COMPONENT LISTING The components of the SL40 that are considered to be field replaceable and for which test and replacement procedures are provided are listed in Table 1 Table 1 Replaceable Components 430 6040 2xx Apollo SL40 Comm Transceiver Description 415 7000 10 SP96 Com Display Board 6010 1 415 7002 00 VHE Com Main Board 6011 1 Although the Com Display board is the actual replaceable component assembly considerations dictate that the complete Display assembly be returned for replacement REPLACEMENT POLICY When troubleshooting procedures identify a failed component in the SL40 contact the Morrow Service Department for a Return Material Authorization RMA number and shipping instructions Do not return the
27. ssecesececessessnseceeeeees HANDLING CONSIDERATIONS ESD PROTECTION COMPONENT HANDLING SHIPPING CONSIDERATIONS SECTION 2 TROUBLESHOOTING 5 OVERVIEW ESD SAFE WORK AREA REQUIREMENTS PRELIMINARY CHECKOUT SYSTEM FUNCTIONS 2 SOFTWARE VERSION DISPLAY SIGNAL STRENGTH DISPLAY AUDIO NOISE LEVEL DISPLAY HEADPHONE LEVEL DISPLAY AND ADJUSTMENT INTERCOM SQUELCH THRESHOLD DISPLAY AND ADJUSTMENT INTERCOM AUDIO LEVEL DISPLAY AND ADJUSTMENT SIDETONE LEVEL DISPLAY AND ADJUSTMENT BASE STATION LOCKOUT MODE DISPLAY AND ADJUSTMENT TEST MODE OPERATION TEST MODE ACCESS GENERAL OPERATION TEST MODE PAGE DISPLAY TEST FUNCTION CONTROLS TEST FUNCTION TEST SETUP EQUIPMENT TESTS TRANSMITTER PERFORMANCE TRANSMITTER FREQUENCY ERROR TRANSMITTER POWER MEASUREMENT TRANSMITTER MODULATION TRANSMITTER SNR SIGNAL TO NOISE RATIO TRANSMITTER AUDIO DISTORTION RECEIVER RECEIVER PERFORMANCE SPEAKER AUDIO TEST RECEIVER SENSITIVITY UNIT DISASSEMBLY REASSEMBLY DISASSEMBLY REASSEMBLY Apollo 5140 Field Maintenance Manual Apollo 5140 Field Maintenance Manual COMPONENT 0000000000000000000000000000000000000000000000000000000000000000000000000 Table of Contents REPLACEABLE COMPONENTS REPLACEMENT POLICY PACKAGING FOR SHIPMENT CONTACTING THE FACTORY FOR ASSIST
28. stall the SL40 in the aircraft Refer to the SL40 Installation Guide 560 0956 for installation instructions The steps that are not applicable to a particular installation may be skipped A test data log sheet is included on page 27 to fill out during the checkout procedure Make a photocopy of the log sheet for ease of use if desired Mounting Wiring Check Verify that all cables are properly secured and shields are connected to the rear of the mounting frame Check the movement of the aircraft controls to verify that there is no interference POST INSTALLATION CHECKOUT Once the unit is reinstalled complete the post installation checkout procedure given in the SLAO Installation Guide 560 0956 to verify proper operation Refer to the Users Guide for operating instructions SIDETONE LEVEL ADJUSTMENT The sidetone volume was preset at the factory to what should be an acceptable level However the level can be adjusted using the built in test mode To adjust the sidetone level 1 Press and hold the and RCL buttons while switching on the unit This will enable the built in test mode 2 Rotate the LARGE knob to display the SIDETONE LVL page 3 Press the the number will flash rotate the small knob to change the level number and press MEM to save the new setting The range of the number is 000 to 255 with 128 producing one half of full rated output 4 Turn the unit off to exit the test mode 5 Turn on the unit select an
29. t the SL40 during manufacture and factory service Alternate but equivalent equipment may be substituted if the recommended equipment is not available OVERVIEW Field maintenance of the SL40 is limited to replacement of the SP96 Com Display Board and the VHF Com Main board ESD SAFE WORK AREA REQUIREMENTS The SL40 circuit boards contain electrostatic discharge sensitive ESDS components To prevent damage to the ESDS components the circuit boards must be removed from the SL40 and handled in an ESD safe work area only The work area must comply with the requirements of IPC 610A or other equivalent document At a minimum observe the following the following precautions when handling SL40 components Both you and the work surface must be properly grounded before handling the SL40 components If moving the SL40 components from one area to another they must either be reinstalled in the SL40 case or placed in an anti static bag PRELIMINARY CHECKOUT Perform the following tests before removing the SL40 from the aircraft to determine if the problem is in the SL40 or the aircraft Transmission and reception range is normally not a problem in aircraft due to the aircraft height above terrain Poor reception range that can be traced to aircraft noise or antenna performance is usually repairable The SL40 has a number of System Functions to assist in isolating Comm problems Two of these features assist the operator or service personnel
30. the Com Main board to allow the connectors to go through the holes in the back of the chassis 2 Ensure that the notch in the upper right corner of the board see Figure 6 is aligned with the tab on the display bezel and push the board down into the chassis If more that a very slight forward pressure on the bezel is required to replace the Com Main board reposition aac is et 5 rel tas iml duod 2 Sah MES 3 Ensure that the holes in the board are aligned with the matching holes in the chassis Start 1 or 2 screws to maintain alignment 4 Secure the 15 pin d sub connector to the rear of the chassis using two 4 40x1 4 flat head screws 5 Using a 9 16 deep well socket fasten the BNC connector to the rear of the chassis with a nut and internally toothed lockwasher 6 Secure the Com Main board to the chassis using ten 4 40x1 4 pan head screws and lockwashers 7 Reconnect the ribbon cable from the display board to J603 on the Com Main board 8 Tilt the SL40 cover so the front edge slides under the tab on the display bezel and position the cover so the screw holes are aligned with the PEM nuts Secure the cover with nine 4 40x3 16 flat head screws Com Display Board Replacement 1 Position the bezel assembly on the front of the chassis so that the screw holes in the bezel align with the holes in the chassis a
31. tons will operate normally during display of the system functions Pressing any button will revert back to the normal mode defined for the button The receiver will also operate normally during display of the system functions SOFTWARE VERSION DISPLAY This function displays the COM software version SIGNAL STRENGTH DISPLAY This function is used to display the signal strength of received signals With a dummy antenna connected this function will normally be in the range 13 to 16 Full transceiver functions are operational during this function including transmit Note The rf signal strength is an 8 bit value with a range of 0 to 255 from the IF RF voltage as read into the controller through A D input AUDIO NOISE LEVEL DISPLAY This function is used to display the noise level of the received audio NOISE 005 With a dummy antenna connected this function will normally be in the range 162 to 170 Full transceiver functions are operational during this function including transmit 6 Apollo 5140 Field Maintenance Manual Troubleshooting Note The noise level is an 8 bit value with a range of 0 to 255 from the noise level detector as read into the controller through an A D input HEADPHONE LEVEL DISPLAY AND ADJUSTMENT This function is used to display and adjust the headphone audio level Turning the small knob changes the value Setting the value to 0 slaves the headphone audio level to the volume control knob Setting to a
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