P/N 1061-4000-XX-001( ) - DAC International · 2015. 8. 28. · 1061-4000-01-001( ) GDC40 Iridium...

Equipment Installation Manual, GDC40 Iridium Interface Unit

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EQUIPMENT INSTALLATION MANUAL

GDC40 IRIDIUM INTERFACE UNIT

P/N 1061-4000-XX-001( )

Rev A

DAC International 6702 McNeil Drive Austin, TX 78729

©Copyright 2006, DAC International. All rights reserved.

bhatcher

Released


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RECORD OF REVISIONS

REV DESCRIPTION DATE APPROVED

IR INITIAL RELEASE, E468 3/10/06 LW A Added acceptable alternative for connector 1/28/09 BH


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Table of Contents RECORD OF REVISIONS ......................................................................................................................................... 2 INTRODUCTION: ...................................................................................................................................................... 4 DESCRIPTION: .......................................................................................................................................................... 4 PART NUMBERS:...................................................................................................................................................... 5 REGULATORY COMPLIANCE: .............................................................................................................................. 5

Software ................................................................................................................................................................... 5 Environmental.......................................................................................................................................................... 5

SUPPLIED EQUIPMENT........................................................................................................................................... 6 SPECIFICATIONS:..................................................................................................................................................... 7

Physical:................................................................................................................................................................... 7 Electrical: ................................................................................................................................................................. 7 Serial Data Input and Output: .................................................................................................................................. 7 Iridium Interface Unit Output .................................................................................................................................. 9 Weight On Wheels Input: ........................................................................................................................................ 9 Panic Button Input: .................................................................................................................................................. 9 Disconnect Button Input: ......................................................................................................................................... 9 Certification: ............................................................................................................................................................ 9 Reliability:................................................................................................................................................................ 9

OPERATION:............................................................................................................................................................ 10 Overview................................................................................................................................................................ 10

INSTALLATION ...................................................................................................................................................... 11 Material Not Supplied............................................................................................................................................ 11 Special Tools.......................................................................................................................................................... 11 Mounting Considerations....................................................................................................................................... 12 Wiring Considerations ........................................................................................................................................... 12

Baud Rate Selection........................................................................................................................................... 12 GPS Receiver Setup........................................................................................................................................... 12

REMOVAL AND REPLACEMENT........................................................................................................................ 13 Removal, GDC40................................................................................................................................................... 13 Replacement, GDC40 ............................................................................................................................................ 13

EQUIPMENT CHECKOUT...................................................................................................................................... 14 Ground Functional Test ......................................................................................................................................... 14

CONTINUED AIRWORTHINESS: ......................................................................................................................... 15 ENVIRONMENTAL:................................................................................................................................................ 16 CONNECTOR PIN OUT: ......................................................................................................................................... 17 OUTLINE DRAWINGS............................................................................................................................................ 18

GDC40 Outline ...................................................................................................................................................... 18 SLIDE LATCH ASSEMBLY.................................................................................................................................... 19 APPENDIX A – DATA FORMATS......................................................................................................................... 20 APPENDIX B - TYPICAL INTERCONNECT ........................................................................................................ 21


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INTRODUCTION:

This manual contains installation data, specifications and Instructions for Continued Airworthiness for the DAC International Model GDC40 Iridium Interface Unit, Part Number 1061-4000-XX-001( ).

DESCRIPTION:

The GDC40 Iridium Interface Unit (IIU) with software version 001( ) is an aircraft accessory designed to receive RS232 serial data from one of four possible positioning systems shown in Figure 1. From that data, it will produce, depending upon initial installation configuration straps, one of four converted data streams according to conversion table shown in Table 1 Serial Data Formats. The GDC40 output signal connects to an existing Iridium ST-3100 satellite phone. The GDC40 does not reduce or otherwise alter any existing safety features of the aircraft. The GDC40 provides geospatial data only.

AMS-3000S

GPS-2003ZZCompatible

NMEA 0183Compatible

FF2101 SeriesCompatible

COMChannel

w/ eitherSBDOR

MobileTerminated

Mode Enabled

PanicButton

DisconnectSwitch

OperationalLED

Binary State Inputs

GDC 40Iridium

Interface Box

19200bpsRS-232C

interface toIridiumPhone

DataConversion

OR

1 of 4 possibledata input formats

configured atinstallation

OR

OR

EXTERNAL

DATA

BUS

9600bpsRS-232Cinterface

A0 PacketData Format


9600bpsRS-232CinterfaceAviation

Data Format


75 PacketData Format

StrapsWeight- on -

Wheels

Figure 1 Interface Block Diagram


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PART NUMBERS:

The GDC40 Iridium Interface Unit is available under the following part numbers:

1061-4000-01-001( ) GDC40 Iridium Interface Unit

REGULATORY COMPLIANCE:

Software

The Model GDC40 software was developed in accordance with RTCA/DO-178B to criticality level E.

Environmental

The Model GDC40 meets the DO-160E environmental categories listed later in this manual.


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SUPPLIED EQUIPMENT

Each Iridium Interface Unit is shipped with the following items: Part Number Description Qty

1061-4000-01-001( ) GDC40 Iridium Interface Unit 1 1061-4200-01 Installation Kit, GDC40 Iridium Interface Unit 1 Complete installation kits are available under kit part number 1061-4200-01. Individual pieces are available under the part numbers shown. Contact DAC International sales to place orders. Part Number Description Qty

1061-4200-01 Installation Kit, GDC40 Iridium Interface Unit M24308/2-3F Connector, Receptacle, 25 pin D-Sub 1 M24308/2-3* Connector, Receptacle, 25 pin D-Sub - P10220 Backshell, 25-Pin D-Sub 1 1061-2510-01 Equipment Installation Manual for the GDC40 1 M39029/63-368 Socket, Crimp Style, female 25 P10219 Slide Latch Kit, shell size 3 1

* - This part is an acceptable alternative to M24308/2-3F and either part may be used in the installation of the Iridium Interface Unit. In the event that this part is used, it shall be used in the quantity listed for M24308/2-3F.


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SPECIFICATIONS:

Physical:

The GDC40 attaches to the airframe via four mounting holes. See the paragraph titled Outline Drawing for further details.

IIU LRU

Height ................................................1.25”

Width .................................................5.22” (Includes mounting flange)

Depth..................................................3.54”

Weight................................................0.4 lb.

Electrical:

Input Voltage .....................................14 / 28 VDC (10Vdc – 32Vdc operational)

Input Current......................................0.1 Amp maximum at 28 VDC

Serial Data Input and Output:

Format................................................RS-232 serial data shall be in one of five formats; NMEA, A0, C0, 75, or Aviation Data format.

RS-232 serial output data shall be in one of three formats; A0, C0, or 51.

Baud Rate...........................................Device dependant (4800, 9600, 19200) Note 1:

Note 1: ...............................................Baud Rate of both Iridium RS-232 and 1-of-4 data source RS-232 is configured at installation via straps on P1 in accordance with Table 1.


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SERIAL DATA FORMATS:

INPUT Serial Data Format OUTPUT Serial Data Format

AMS-3000S Iridium PhoneA0 packet only

FF2101 AMS-3000SAviation Data A0 packet only

NMEA Device GPS-2003ZZGGA / VTG / RMC 75 packet only

Sentences

GPS-2003ZZ75 packet only

Iridium PhoneC0 packet only

9600 BPS, 8 Data, 1 Stop, No parity

9600 BPS, 8 Data, 1 Stop, No parity

GD

C 40 Physical Interface

19,200 bps, 8 data, 1 stop bit and no PARITYA0, C0 or 51 packet

Only

19,200 bps, 8 data, 1 stop bit and no PARITY

4800bps, 8 data, 1 stop, No parity

9600 bps, 8 data, 1 stop, No parity



Table 1 Serial Data Formats


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Iridium Interface Unit Output

Description.........................................RS-232 configured with 8 data bits, 1 stop bit and no parity. 19,200 bps communication with the Iridium phone, 9600 bps to the Airmap system, 9600 bps to the FF2101 compatible system, 4800 bps to the NMEA compatible system and 9600 bps to the GPS2003 compatible system.

Weight On Wheels Input:

Description.........................................Discrete inputs to the GDC40 at J1-09 and J1-13 supplied from a weight-on-wheels switch.

Normal: (J1-13 Open)........................Open = In Air Ground = On Ground

Reverse: (J1-13 Ground)....................Ground = In Air Open = On Ground

Panic Button Input:

Description.........................................Discrete input to the GDC40 at J1-22 supplied from a N.O. SPST switch.

Voltage:..............................................Normally open being Hi-Z, Closed (switch pushed) being 0V.

Disconnect Button Input:

Description.........................................Discrete input to the GDC40 at J1-10, supplied from a N.O. SPST switch.

Voltage:..............................................Normally open being Hi-Z, Closed (switch pushed) being 0V.

Certification:

DO-178B............................................Level E

DO-160E............................................B1/CACUXXXXXXZBABATM/XXE1X/XXA

Reliability:

MTBF ................................................Greater than 50,000 hours.


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OPERATION:

Overview

The GDC40 Iridium Interface Unit receives RS232 serial data in NMEA, A0, C0, 75 or Aviation formatted navigation data from any one of four devices and enables communication of that data to an Iridium Satellite phone. The IIU extracts information from the data stream of the GPS/Airmap system and converts the format of the data into the selected format according to instructions received from the configuration packet previously received by the Iridium Satellite phone during initialization of the system.


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INSTALLATION

This section provides details for the installation of the GDC40 Iridium Interface Unit, including configuration, wiring, mounting and checkout procedures. Follow the procedures and recommendations found in this section to assure a successful installation. Read this entire section before beginning the installation. Complete an electrical load analysis in accordance with AC 43.13-1B, Chapter 11 prior to starting the aircraft modification to insure the aircraft has sufficient load capability. Complete an aircraft weight and balance prior to aircraft modification to insure the aircraft has sufficient weight and CG margin.

Material Not Supplied

The following items are required for the installation but not supplied: • Wire: MIL-W-22759/16 or equivalent • Shielded Wire: MIL-C-27500 or equivalent • Mounting screws: MS35206 6-32, 4 each • Circuit Breaker: Klixon 7277-2-2 or equivalent • Tie straps or lacing cord • Ring terminals (for grounding) • Splices

Special Tools

Use the following crimp tool to ensure reliable crimp contact connections to connector J1. • Crimp tool M22520/2-01 • Positioner M22520/2-08


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Mounting Considerations

The GDC40 Iridium Interface Unit can mount in the avionics bay, shelf or other suitable structure. It can be mounted in any orientation.

Wiring Considerations

Wiring should be done in accordance with AC 43.13-1B, Chapter 11. Refer to the typical interconnect diagram later in this manual for specifics. Use 22 to 24 AWG wire for all connections. Fabricate wiring harness; refer to the interconnect diagrams and pin description. Test all the wiring for continuity and for shorts. Insure aircraft power is on the correct pins of J1; refer to Table 6. Install slide latch assembly onto J1 using instructions found later in this manual. Baud Rate Selection

The GDC40 will accept three (3) baud rates for data configured by grounding pins P1-06 and P1-19 during cable assembly.

Equipment Baud Rate*

J1-06 J1-19

AMS-3000S 9600 Ground Ground FF2101

compatible 9600 Ground Open

NMEA compatible 4800 Open Ground

GPS-2003 compatible 9600 Open Open

Table 2 Baud Rate Selection *Note: Data transmission to Iridium phone is at 19200 bps regardless of data source rate selection GPS Receiver Setup

Refer to the manufacturer's instructions for the GPS interfaced to the GDC40 IIU. Configure the GPS to output the Aviation Format data described in Appendix A.


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REMOVAL AND REPLACEMENT

Removal, GDC40

1. Open the circuit breaker powering the GDC40.

2. Remove the connector by disengaging the slide latch then pulling the connector free.

3. Remove four (4) screws securing the unit to the airframe.

Replacement, GDC40

1. Open the circuit breaker powering the GDC40.

2. Attach the unit to the airframe with four (4) screws.

3. Seat the connector then engage the slide latch to secure.

4. Close circuit breaker.

5. Perform ground functional test found under Equipment Checkout in this manual.


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EQUIPMENT CHECKOUT

There are no operator controls associated with the GDC40 unit. The GPS receiver, Iridium phone and the Airmap system, if installed, must all be operational in order to perform this functional checkout.

Ground Functional Test

1. Perform GPS Receiver and Iridium phone installation and functional test. 2. Power up GPS receiver, Iridium phone and GDC40. 3. Using ground station, provide interrogation of Iridium phone system and validate correct response received

at ground station. 4. Remove phone from cradle – annunciator lamp should illuminate steady, replace the phone in cradle –

annunciator lamp should extinguish. 5. Depress panic button – annunciator lamp should blink, release panic button – annunciator lamp should

extinguish.


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CONTINUED AIRWORTHINESS:

This section provides data intended to assist the installer with establishing instructions for Continued Airworthiness as required by FARs 23.1529, 25.1529, 27.1529 and 29.1529. 1. Maintenance Manual information for the GDC40, which includes system description, removal instructions,

installation instructions and functional testing instructions, is contained in DAC International Installation Manual, 1061-2510-01 (this document).

2. Line Replaceable Unit (LRU) part numbers and other parts contained in the installation data package should

be placed in the aircraft operator’s appropriate airplane Illustrated Parts Catalog (IPC). 3. Wiring diagram information contained in the installation data package should be placed in the aircraft

operator’s appropriate airplane Wiring Diagram Manual. 4. Scheduled Maintenance Program tasks are as follows:

a. Recommended Periodic Scheduled Servicing: ............................None required b. Recommended Periodic Scheduled Preventive Maintenance Tests .......................................................................None Required c. Recommended Periodic Inspections:...........................................None Required d. Recommended Periodic Overhaul Period....................................None Required e. Special Inspection Requirements.................................................None Required

5. Application of Protective Treatments.....................................................None Required 6. Special Tools ..........................................................................................None Required 7. Electrical Loads for this appliance are as specified in the DAC International Installation Manual, 1061-2510-

01 (this manual). 8. There are no Airworthiness limitations associated with the installation of this appliance.


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ENVIRONMENTAL:

The GDC40 meets the environmental test categories detailed below in accordance with RTCA/DO-160D, Environmental Conditions and Test Procedures for Airborne Equipment. NOMENCLATURE: Model GDC40 Iridium Interface Unit PART NO: 1061-4000-XX-XXXX MANUFACTURER: DAC International ADDRESS: 6702 McNeil Drive, Austin, TX 78729

Section Category Remarks 4.0 Temperature and Altitude B1 Non-press, non-temperature

controlled, altitude 25,000 ft 5.0 Temperature Variation C 2°C degrees per minute 6.0 Humidity A Standard Humidity 7.0 Operational Shock and Crash Safety C Helicopters

8.0 Vibration U Helicopter, Unknown Frequencies

9.0 Explosion Proofness X Not Tested 10.0 Waterproofness X Not Tested 11.0 Fluids Susceptibility X Not Tested 12.0 Sand and Dust X Not Tested 13.0 Fungus Resistance X Not Tested 14.0 Salt Spray X Not Tested 15.0 Magnetic Effect Z Less than 0.3 meter 16.0 Power Input B DC equipment driven by

ALTs/RECTs with battery on bus 17.0 Voltage Spike B 56 volts 18.0 AF Conducted Susceptibility – Power Inputs

B Alternator / Rectifiers 19.0 Induced Signal Susceptibility A 20.0 Radio Frequency Susceptibility (Radiated and Conducted)

T 5 volts/meter 21.0 Emission of Radio Frequency Energy M Cockpit or passenger area 22.0 Lightning Induced Transient Susceptibility

XXE1X Waveform E, Level 1

23.0 Lightning Direct Effects X Not Tested 24.0 Icing X Not Tested 25.0 ESD A

Table 3 Environmental Requirements


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CONNECTOR PIN OUT:

The GDC40 contains a single 25-pin male connector, J1, per MIL-C-24308. The mating connector, P1, is described previously under the section “Equipment Supplied”.

Pin Signal Function 1 A+ 28 Vdc Primary Power (Input) 2 ACRFTTX Aircraft Equipment RS232 Transmit (Non-Iridium) (Out) 3 ACRFTRX Aircraft Equipment RS232 Receive (Non-Iridium) (In) 4 GND RS232 Common 5 BusyLight1 Iridium Busy Light Relay Output 6 HiBitDevSel Input Device Configuration Pin (Do Not Apply Voltage) 7 IridTX Iridium Transmit RS232 (Out) 8 IridRX Iridium Receive RS232 (In) 9 WonWheel Weight on Wheel Sensor Input (In)

10 DISCON Iridium Disconnect Switch Input (Do Not Apply Voltage) 11 Reserve Spare Discrete 12 13 /WeightOnWheels WonWheel Logic Selection (N.O./N.C. switch) 14 Power Common 28 Vdc Return 15 GND Chassis Ground 16 Serial Common RS232 Common 17 RESERVED (/PGM Enable)18 BusyLight2 Iridium Busy Light Relay Input 19 LoBitDevSel Input Device Configuration Pin (Do Not Apply Voltage) 20 RTS Iridium RTS Signal (Out) 21 CTS Iridium CTS Signal (In) 22 PANIC Operator Panic Input (Do Not Apply Voltage) (In) 23 ST_Ring_Indicator Iridium Ring Indicator (In) 24 25

Table 4 J1 Pin Description


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OUTLINE DRAWINGS

GDC40 Outline

Figure 2 GDC 40 Enclosure Dimensions Note: Dimensions are in inches.


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SLIDE LATCH ASSEMBLY

Assemble the slide latch mechanism, part number P10219, onto the mating connector as pictured using the hardware supplied with the slide latch.

SLIDE LATCH

SCREW

CONNECTOR

FLAT WASHER

NUT

LOCK WASHER

Figure 3 Slide Latch Assembly


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APPENDIX A – DATA FORMATS

The following table contains the minimum data set required by the GDC40. The GDC40 is designed to disregard additional data records transmitted to it. Insure the GDC40 is configured for the correct baud rate (refer to "Serial Baud Rate Selection" located earlier in this manual)

Data Packet Formats Description

A0 AMS-3000S Airmap system Aviation FF2101 Compatible system 51 or 75 GPS-2003 Compatible system NMEA GGA & VTG or RMC

NMEA Compatible system

Table 5 Data Packet Formats


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APPENDIX B - TYPICAL INTERCONNECT

The following section contains typical interconnect diagrams to aid in wiring the GDC40.

Equipment Installation Manual, Iridium Interface Unit

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SUPPLYPOWER

NOTE: PINS 6, 19, AND 13 ARE CONFIGURED AT INSTALLATION.

COMMONCHASSIS

+28VDC

AIRCRAFT TRANSMITAIRCRAFT RECEIVE

PANIC BUTTONDISCONNECT BUTTON

WEIGHT-ON-WHEELS INPUT

BUSY LIGHT INBUSY LIGHT OUT

IRIDIUM TRANSMITIRIDIUM RECEIVE

RTSCTS

/WEIGHT-ON-WHEELS SELECTLO BIT DEVICE SELECTHI BIT DEVICE SELECT

GDC40

INTERFACEBUSY LIGHT

IRIDIUM ST3100/

INTERFACEEMERGENCYHARDWARE/

MAPPINGGPS/

13196

212087

185

9102232

15141

0.5A

+28VDC BUS

Figure 4 Interface Connection Drawing


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8IRIDRX

LOBITDEVSELHIBITDEVSEL

WEIGHTonWHEELS

19

13

6

GND 421CTS

RTS 20

IRDITX

BUSYLIGHT2BUSYLIGHT1

7

185

WonWHEELS

DISCON

PANIC

10

9

22

15GND

SER COMACRFTRXACRFTTX

316

2

PWR COM 14A+ 1

NOT ON GROUNDON GROUND

OPENWEIGHTonWHEELS

WEIGHT-ON-WHEEL RELAY

DISCONNECT SW

PANIC SW

ON GROUNDNOT ON GROUND

WonWHEELSGND

MODEM GND

ST3100

LEDBUSY LIGHT

0.5A FUSE

GNDAUX-TX

AUX 6AMS-3000S

A+

A+

AUX-RXAUX 9AUX 5

c

GDC40

GNDOPEN

NaXS

RS232 TXRS232 RX

RS232 RTSRS232 CTS

Figure 5 GDC40 and AMS-3000S Interface Drawing


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8IRIDRX


WEIGHTonWHEELS

19

13

6

GND 421CTS

RTS 20

IRDITX


7

185

WonWHEELS

DISCON

PANIC

10

9

22

15GND


316

2

PWR COM 14A+ 1


OPENWEIGHTonWHEELS

NC


DISCONNECT SW

PANIC SW


WonWHEELSGND

c

ST3100

LEDBUSY LIGHT

0.5A FUSE

A+

COM

FF2101

NONE

A+

10

J1

TX1

MODEM GND

GDC40

GNDOPEN

NaXS

RS232 TXRS232 RXRS232 RTSRS232 CTS

Figure 6 GDC40 and FF2101 Interface Drawing


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8IRIDRX


WEIGHTonWHEELS

19

13

6

GND 421CTS

RTS 20

IRDITX


7

185

WonWHEELS

DISCON

PANIC

10

9

22

15GND


316

2

PWR COM 14A+ 1


OPENWEIGHTonWHEELSNC (OPEN)


DISCONNECT SW

PANIC SW


WonWHEELSGND

MODEM GND

ST3100

LEDBUSY LIGHT

SER COM

0.5A FUSE

-

A+

NMEA TXD

A+

c

GDC40

GPS NMEA OUTPUT

NaXS

GNDOPEN


Figure 7 GDC40 and GPS NMEA OUTPUT Interface Drawing


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8IRIDRX


WEIGHTonWHEELS

19

13

6

GND 421CTS

RTS 20

IRDITX


7

185

WonWHEELS

DISCON

PANIC

10

9

22

15GND


316

2

PWR COM 14A+ 1


OPENWEIGHTonWHEELS


DISCONNECT SW

PANIC SW


WonWHEELSGND

MODEM GND

ST3100

LEDBUSY LIGHT

0.5A FUSE

GPS-2003ZZ

A+

2

53

A+

RXDTXDCOM

c

GDC40

NC (OPEN)NC (OPEN)

NaXS


GNDOPEN

Figure 8 GDC40 and GPS-2003ZZ Interface Drawing

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P/N 1061-4000-XX-001( ) - DAC International · 2015. 8. 28. · 1061-4000-01-001( ) GDC40 Iridium...

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