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VCS-40A VHF Communication System
Installation Manual
150-040984, Rev K
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VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Wulfsberg Electronics, A Cobham Avionics & Surveillance Group Company, located in Prescott,
Arizona, designs and manufactures the Wulfsberg Electronics Series III line of products, including
the VCS 40A VHF Communication System. For more than 25 years, Wulfsberg Electronics has
distinguished itself by providing top quality avionics products for civil, air transport, and military
applications.
Wulfsberg Electronics makes no warranty, expressed or implied, with regard to this manual,
including but not limited to any implied warranties of merchantability, fitness for a particular
purpose, and non-infringement. In addition, Wulfsberg Electronics makes no warranty with regard
to the documentation or data contained herein. Wulfsberg Electronics is not liable in the event of
incidental, special, consequential, or any other damages in connection with or arising from
furnishing, performance, or use of this manual.
Reproduction of this publication or any portion thereof by any means is prohibited. For further
information contact Sales, Wulfsberg Electronics 6400 Wilkinson Drive, Prescott, Arizona, 86301.
Telephone: (928) 708-1500.
Information in this manual is subject to change without notice.
© 2001 Wulfsberg Electronics. All rights reserved
VCS 40A, VC-401B, and CD-402B are trademarks of Wulfsberg Electronics.
PROPRIETARY NOTICE
This document contains proprietary information and such information may not be disclosed to
others for any purpose, nor used for manufacturing purposes without written permission from
Wulfsberg Electronics.
Page ii
Table of Contents
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Record of Revisions
Rev
No.
Rev
Date
A
4/2001
B
7/2001
C
7/2001
D
11/2001
E
4/2002
F
10/2003
G
8/2004
H
12/2004
J
3/2005
K
3/2007
Date
Inserted
Publication No. 150-040984
Rev. K
By
Rev
No.
Rev
Date
Date
Inserted
By
Page iii
Table of Contents
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Record of Revisions
Rev
No.
Rev
Date
Date
Inserted
Page iv
Table of Contents
Mar 2007
By
Rev
No.
Rev
Date
Date
Inserted
By
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
TABLE OF CONTENTS
Section
Page
SECTION 1 – GENERAL INFORMATION
1.
Introduction ...............................................................................................................................1-1
2.
Applicability................................................................................................................................1-1
3.
Equipment Description .............................................................................................................1-1
A. VC-401B VHF Communications Transceiver....................................................................1-1
B. CD-402B Control Display Unit ..........................................................................................1-1
4.
Available Configuration Variations ............................................................................................1-2
5.
Technical Specifications ...........................................................................................................1-3
6.
Installation Kits and Accessories ..............................................................................................1-6
A. VC-401B Connector Kits ...................................................................................................1-6
B. CD-402B Connector Kits ..................................................................................................1-7
C. Dual Mounting ...................................................................................................................1-7
7.
Accessories Required But Not Supplied .................................................................................1-10
8.
Tools Required But Not Supplied ............................................................................................1-10
9.
License Requirements.............................................................................................................1-10
SECTION 2 – INSTALLATION
1.
General......................................................................................................................................2-1
2.
Unpacking and Inspecting Equipment ......................................................................................2-1
3.
Equipment Installation ..............................................................................................................2-1
A. Cooling Considerations ....................................................................................................2-1
B. VC-401B Mechanical Installation .....................................................................................2-1
C. Dual Installation Considerations........................................................................................2-2
D. VC-401B Harness and Connector Assembly .................................................................2-11
E. CD-402B Mechanical Installation ...................................................................................2-19
F. Antenna Installation ........................................................................................................2-23
G. Optional Strapping ..........................................................................................................2-23
4.
Post-Installation Check............................................................................................................2-24
A. System Test ...................................................................................................................2-24
B. Flight Check ...................................................................................................................2-24
SECTION 3 – OPERATION
1.
General .....................................................................................................................................3-1
APPENDIX A - PRODUCT CROSS REFERENCE ......................................................................... A-1
Publication No. 150-040984
Rev. K
Page v
Table of Contents
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
LIST OF FIGURES
Figure
Page
2-1
Three Radio System Transmit Interlock Wiring ................................................................2-3
2-2
VC-401B Outline Drawing .................................................................................................2-5
2-3
Mounting Tray Envelope Drawing 4-inch (2 Sheets) ........................................................2-7
2-4
RF Cable Fabrication ......................................................................................................2-11
2-5
VC-401B Rack Mount Connector....................................................................................2-12
2-6
VC-401B Polarizing Post Assembly ................................................................................2-15
2-7
VCS 40A Interconnect Diagram ......................................................................................2-17
2-8
CD-402B Cable Connector Assembly.............................................................................2-19
2-9
CD-402B Outline Drawing ...............................................................................................2-21
LIST OF TABLES
Table
Page
1-1
VC-401B Configuration Variations .......................................................................................1-2
1-2
CD-402B Configuration Variations .......................................................................................1-2
1-3
VC-401B Specifications........................................................................................................1-3
1-4
CD-402B Specifications........................................................................................................1-5
1-5
VC-401B Connector Kit (050-02398-0000, Rev. 3)..............................................................1-6
1-6
VC-401B Mounting Tray 4 Inch, Safety Wire Compatible ....................................................1-6
1-7
VC-401B Mounting Tray 4 Inch, Non-Safety Wire Compatible ............................................1-6
1-8
CD-402B Installation Kit (050-02372-0000, Rev. D) ............................................................1-7
1-9
VC-401B Mounting Tray, Dual, 4 Inch, Safety Wire Compatible..........................................1-7
1-10
VC-401B Mounting Tray, Dual, 4 Inch Non-Safety Wire Compatible ...................................... 1-8
1-11
VC-401B Mounting Rack Adapter Kit (050-02376-0000, Rev EB).......................................1-9
1-12
CD-402B Mount Adapter Kit (071-01356-0000, Rev. F) ......................................................1-9
1-13
CD-402B Mount Adapter Kit (071-01356-0001, Rev. F) ......................................................1-9
2-1
VC-401B Pin-outs...............................................................................................................2-13
2-2
CD-402B Pin-outs...............................................................................................................2-20
2-3
Strapping Options...............................................................................................................2-23
Page vi
Table of Contents
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
SECTION 1 – GENERAL INFORMATION
1.
Introduction
This section contains information relative to the physical, mechanical, and electrical
characteristics of the Wulfsberg VCS 40A VHF Communications System.
2.
Applicability
This manual applies only to VC-401B Transceivers, Mod 22 and higher, and CD-402B Control
Displays, Mod 5 and higher. For units below Mod 5, refer to Installation Manual No. 006-006940009.
3.
Equipment Description
The Wulfsberg VCS 40A VHF Communications System is a fully synthesized ATC VHF
transceiver with TSO certification to TSO-37c and TSO-38c that provides a voice/data
communications link between the aircraft and ground facilities. The VCS 40A system consists of a
lightweight, remote-mounted VC-401B transceiver and a panel-mounted CD-402B Control
Display.
A. VC-401B VHF Communications Transceiver
The VC-401B VHF Communications Transceiver is available with fixed 25 kHz channel
spacing, fixed 8.33 kHz channel spacing, and switchable 25 kHz - 8.33 kHz channel spacing.
Operation within the frequency range of 118.00 – 136.975 MHz is standard. Extended
operation within the frequency range of 118.00 – 151.975 MHz is available as an option.
The VC-401B is designed for rack mounting. The case is fitted with a handle on the front
panel for ease of handling during installation and removal.
The VC-401B consists of functional subassemblies interconnected via ribbon cables. The
subassemblies or circuit modules are hinged and attached to rigid, durable main frames
permitting easy access removal for service. Adjustments and test points are exposed and
available to the service technician without having to remove circuit module subassemblies or
use extender cables or cards.
Circuit modules are plug-in, enabling fault isolation through module substitution. A single
connector accepts all harness wiring on the rear of the VC-401B, while a BNC type RF
connector provides the VHF antenna connection through conventional coaxial cable.
B. CD-402B Control Display Unit
The CD-402B Control Display Unit is designed to be mounted in the instrument panel
individually, or combined in pairs in an adapter plate that will fit a standard DZUS mounting.
Front panel controls establish and display the operating status of all VC-401B functions.
Nonvolatile memory is used to retain the last frequency used, thus eliminating frequency
changes as a result of momentary or extended power disruptions.
Publication No. 150-040984
Rev. K
Page 1-1
Section 1 – General Information
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
The system uses full-time self-test to monitor key internal circuits and to display the word
"FAIL" followed by a preassigned number to indicate which specific module has failed. Refer
to the Pilot’s Guide for FAIL message details.
The system is designed for compatibility with ARINC Characteristic 429 Digital Information
Transfer System to allow external frequency control of the VHF communications system. It is
also ACARS and Selcal compatible.
4.
Available Configuration Variations
The following tables list the currently available configuration variations of the VC-401B and the
CD-402B.
Table 1-1. VC-401B Configuration Variations
Options for VC-401B
064-1047-XX
XX=
01
Frequency
136.975 MHz
Range
151.975 MHz
X
Audio &
10 mW
X
Sidetone
20 mW
40 mW
8.33 kHz
21
22
31
X
X
32
50
X
X
X
51
X
53
54
X
X
X
X
X
X
X
Mod
17 or 22
X
X
X
X
X
62
X
X
X
X
X
X
X
X
Bezel Color
X
X
Gray
Panel Lighting
Options
5V
28 V
AC Gnd Iso.
X
Volume
X
8.33 SW
Page 1-2
Section 1 – General Information
Mar 2007
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XX= 00 02 07 16 50 51 52 53 54 55 56 57 58
Black
65
X
Table 1-2. CD-402B Configuration Variations
Options for CD-402B
071-1341-XX
64
X
X
X
63
X
X
Switchable
ICAO Compliant
61
X
X
X
X
60
X
X
Fixed
55
X
X
X
52
X
X
X
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
5.
Technical Specifications
Table 1-3. VC-401B Specifications
CERTIFICATION:
Transmitter
TSO-C37c, DO-186A Class 3 & 5, and EUROCAE ED-23B.
Receiver
TSO-C38c, DO-186A Class C & E, ICAO Annex 10, and EUROCAE ED-23B.
Intermodulation
Paragraph 2.2.10 (EUROCAE ED-23B, Section 3.1.10)
Desensitization
Paragraph 2.2.11 (EUROCAE ED-23B, Section 3.1.11)
FCC IDENTIFICATION:
FRWVC-401B
TEMPERATURE RANGE:
Operational
-55° C to +70° C (-67° F to +158° F)
Storage
-55° C to +85° C (-67° F to +185° F)
COOLING:
Free air circulation
ALTITUDE:
55,000 feet (16,764 meters)
WEIGHT:
6.0 lbs. maximum (2.72 kg)
Single mounting tray
0.97 lbs. maximum (0.44 kg)
Dual mounting tray
2.88 lbs. Maximum (1.31 kg)
OVERALL DIMENSIONS:
Height:
4.00 inches maximum (101.60 mm)
Width:
4.10 inches maximum (104.14 mm)
Length:
13.30 inches maximum (337.82 mm)
INPUT POWER REQUIREMENTS:
Receive
Transmit
(NORM)
24.8 to 30.3 Vdc, 0.66 Ampere @ 24.8 V
(EMER)
20.0 Vdc, 0.80 Amperes
(NORM)
24.8 to 30.3 Vdc, 5.7 Amperes @ 24.8 V
(EMER)
20.0 Vdc, 6.1 Amperes
FREQUENCY RANGE:
118.000 MHz to 136.975 MHz
118.000 MHz to 151.975 MHz optional
FREQUENCY STABILITY:
± 2.5 PPM
CHANNEL SPACING:
8.33 kHz Fixed, 25 kHz Fixed, 8.33/25 kHz Switchable
Continues…
Publication No. 150-040984
Rev. K
Page 1-3
Section 1 – General Information
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 1-3. VC-401B Specifications (Cont'd)
FREQUENCY CONTROL:
Gray Code/ARINC 429
Label
Description
TX(Out)
RX(In)
Eq. ID
notes
BCD BNR
030
25 kHz
X
X
not 04D
X
047
8.33 kHz
X
X
not 033, 10A,
10B
X
The VC-401B has two ARINC 429 buses. Data received on either of the ARINC input channels will
tune the radio. ARINC data with a label of 030 will tune the radio to a 25 kHz channel. ARINC data
with a label of 047 will tune the radio to an 8.33 kHz channel if the radio has 8.33 kHz capability. The
VC-401B re-transmits the frequency it is currently tuned to over the output ARINC 429 buses.
Frequencies on 25 kHz channels have an ARINC label of 030. Frequencies on 8.33 kHz channels
have an ARINC label of 047. No radio BIT status is transmitted.
RF POWER OUTPUT:
20 Watts nominal, 16 Watts minimum over temperature
DUTY CYCLE:
1 min on 4 min off, continuous at reduced power without damage to unit.
HARMONIC CONTENT:
60 dB down from carrier minimum
SPURIOUS CONTENT OF
OUTPUT:
80 dB down from carrier minimum
MODULATION CAPABILITY:
85% minimum with 95% limiting @ 1 kHz
MODULATION FIDELITY:
4 dB maximum variation in modulation percentage,
350 Hz to 2500 Hz
RECEIVER SENSITIVITY:
2.0 μV maximum for 6 dB (S+N)/N (hard)
NOISE LEVEL:
30 dB minimum (S+N)/N ratio for 100 μV
SELECTIVITY:
25 kHz MODE:
6 dB maximum at ± 10 Hz, 60 dB minimum ± 25 Hz
8.33 kHz MODE:
-6 dB maximum at ± 3.55 Hz, -60 dB minimum ± 5.05 Hz
AGC RANGE:
3 dB maximum variation, 5 to 500,000 μV
AUDIO OUTPUT:
10 mW into 600 ohm loads for -01, -32, -50, -51, -60, -61
20 mW into 600 ohm loads for -31, -52, -53, -62, -63
40 mW into 600 ohm loads for -21, -22, -54, -55, -64, -65
AUDIO RESPONSE:
3 dB maximum variation, 350 Hz to 2500 Hz
40 dB minimum attenuation at 4000 Hz
AUDIO DISTORTION:
Receive
25% maximum at rated output (85% modulation at
100-100,000 μV)
Transmit
10% maximum (85% modulation), 350 Hz to 2500 Hz
AUDIO INPUT:
Dynamic or carbon microphone, 250 mV minimum
Continues…
Page 1-4
Section 1 – General Information
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 1-3. VC-401B Specifications (Cont'd)
SIDETONE OUTPUT:
10 mW into 600 ohms (90% modulation) for -01, -32, -50, -51, -60, -61
20 mW into 600 ohms (90% modulation) for -31, -52, -53, -62, -63,
40 mW into 600 ohms (90% modulation) for -21, -22, -54, -55, -64, -65
SIDETONE FIDELITY:
6 dB maximum variation, 350 Hz to 2500 Hz
DATA KEY:
Grounded with PTT for XMIT
VOICE KEY:
Open for REC
DATA IN:
0 dBm (.77 Vrms) at 1000 Hz, 85% modulation
DATA OUT:
0 dBm (.77 Vrms)
VOICE/DATA:
Open for voice, grounded for data
Table 1-4. CD-402B Specifications
TSO COMPLIANCE:
TSO-C37c, TSO-C38c, DO-186A, and EUROCAE ED-23B.
DO-160C Env. Cat. F1XBA(MNY)XXXXXXABABATAXXX EUROCAE ED-14A.
ALTITUDE:
55,000 feet (16,764 meters)
TEMPERATURE RANGE:
Operational
-20°C to +55°C (-4°F to +131°F)
Storage
-55°C to +85°C (-67°F to +185°F)
COOLING:
Convection and Radiation
WEIGHT:
0.80 lbs. maximum (0.363 kg)
OVERALL DIMENSIONS:
Height
3.15 inches maximum (80.01 mm)
Width
2.50 inches maximum (63.50 mm)
Length
4.39 inches maximum (111.51 mm)
INPUT POWER:
Supplied from VC-401B
DISPLAY BACKLIGHTING
CURRENT:
28 Vdc
100 mA ± 10% at maximum brightness
5 Vdc
500 mA ± 10% at maximum brightness
PANEL LAMP CURRENT:
28 Vdc
96 mA ± 10% at maximum brightness
5 Vac or dc
460 mA ± 10% at maximum brightness
HEATER CURRENT:
40 mA ± 10% at 28 Vdc
On at 0° ± 5°C (32° ± 9°F)
Off at approx. 10°C (50°F)
TUNING CONTROL:
Gray Code
Publication No. 150-040984
Rev. K
Page 1-5
Section 1 – General Information
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
6.
Installation Kits and Accessories
A. VC-401B Connector Kits
Installation of the VC-401B requires a connector kit, P/N 050-02398-0000 (see Table 1-5)
and a mounting tray P/N 071-04047-0000 (see Table 1-6).
Table 1-5. VC-401B Connector Kit (050-02398-0000, Rev. E)
PART NUMBER
DESCRIPTION
U/M
QTY
030-02704-0000
CONNECTOR DPXBMA-A106-33P-03FO
each
1
030-01311-0000
CONTACT, PIN, CRIMP
each
106
089-06008-0005
SCREW, FHP 4-40 X 5/16
each
4
156-041929-01
LABEL, MOUNTING TRAY CONNECTOR KIT,
VC-401B, VC-401C, VN-411B, DM-441B, CDM-451
each
1
Table 1-6.
VC-401B Mounting Tray, 4 Inch, Safety Wire Compatible (071-04047-0000, Rev. L)
PART NUMBER
DESCRIPTION
U/M
QTY
154-04047
ENVELOPE DRAWING, MOUNTING TRAY, 4
INCH
RF
RF
400-04047
FINAL ASSEMBLY, MOUNTING TRAY, 4 INCH
RF
RF
200-07788-0000
PARTS LIST, ASSEMBLY, MOUNTING TRAY, 4
INCH, SAFETY WIRE COMPATIBLE
EA
1
156-041904-01
TSO LABEL, MOUNTING TRAY, 4 INCH
EA
1
Table 1-7.
VC-401B Mounting Tray, 4 Inch, Non-Safety Wire Compatible (071-04047-0002, Rev A)
PART NUMBER
DESCRIPTION
U/M
QTY
154-04047
ENVELOPE DRAWING, MOUNTING TRAY, 4
INCH
RF
RF
400-04047
FINAL ASSEMBLY, MOUNTING TRAY, 4 INCH
RF
RF
200-07788-0002
PARTS LIST, ASSEMBLY, MOUNTING TRAY, 4
INCH, NON-SAFETY WIRE COMPATIBLE
EA
1
156-041904-01
TSO LABEL, MOUNTING TRAY, 4 INCH
EA
1
Page 1-6
Section 1 – General Information
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
B. CD-402B Connector Kits
Installation of the CD-402B requires a connector kit P/N 050-02372-0000 (see Table 1-7).
Table 1-8. CD-402B Connector Kit (050-02372-0000, Rev. D)
PART NUMBER
DESCRIPTION
U/M
each
QTY
030-02703-0000
CONNECTOR RD25F110JVL
1
030-01058-0000
CONNECTOR PLUG, KEYING
each
2
035-01762-0002
BAG POLY CLEAR
each
0
156-041921-01
LABEL, INSTALLATION KIT, CD-4XXX
each
1
C. Dual Mounting
When installing dual systems, use mounting tray kit 071-04047-0001 (see Table 1-8). This kit
includes two of the mounting trays listed above, plus an adapter kit P/N 050-02376-0000 (see
Table 1-9). Two connector kits (050-02398-0000) are also needed.
Table 1-9.
VC-401B Mounting Tray, Dual, 4 Inch, Safety Wire Compatible (071-04047-0001, Rev M)
PART NUMBER
DESCRIPTION
U/M
QTY
154-04047
ENVELOPE DRAWING, MOUNTING TRAY, 4 INCH RF
RF
400-04047-0001
ASSEMBLY, MOUNTING TRAY, DUAL 4 INCH
RF
RF
071-04047-0000
PARTS LIST, MOUNTING TRAY, 4 INCH, SAFETY
WIRE COMPATIBLE
each
2
047-07849-0003
GROUND STRAP
each
4
089-08485-0006
WASHER, EXTOOTH #6
each
8
200-07765-0001
PARTS LIST, BRACKET SUPPORT, LEFT
each
1
200-07765-0003
PARTS LIST, BRACKET SUPPORT, RIGHT
each
1
200-07757-0001
PARTS LIST, BRACKET, MOUNTING
each
4
091-00477-0001
ISOLATION GROMMET
each
8
089-05931-0005
SCREW, BHP 6-32 X 5/16
each
8
089-06008-0004
SCREW, FHP 4-40 X 1/4
each
8
089-06008-0005
SCREW, FHP 4-40 X 5/16
each
28
076-01763-0000
BUSHING SHIELD 6-32
each
8
076-01764-0000
BUMPER TRAY .255
each
1
155-05659
INSTRUCTION SHEET, DUAL TRAY KIT
each
1
047-09832-0002
CABLE BRACKET ASSY
each
1
091-00109-0001
CABLE TIE .315
each
1
089-05903-0004
SCREW, PHP 4-40 X 1/4
each
2
156-041909-01
AVERY LABEL, MOUNTING TRAY, DUAL, 4 INCH,
SAFETY WIRE COMPAIBLE
each
1
Publication No. 150-040984
Rev. K
Page 1-7
Section 1 – General Information
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 1-10. VC-401B Mounting Tray, Dual, 4 Inch, Non-Safety Wire Compatible
(071-04047-0003, Rev L)
PART NUMBER
DESCRIPTION
U/M
QTY
154-04047
ENVELOPE DRAWING, MOUNTING TRAY, 4 INCH RF
RF
400-04047-0001
ASSEMBLY, MOUNTING TRAY, DUAL 4 INCH
RF
RF
071-04047-0002
PARTS LIST, MOUNTING TRAY, 4 INCH, NONSAFETY WIRE COMPATIBLE
each
2
047-07849-0003
GROUND STRAP
each
4
089-08485-0006
WASHER, EXTOOTH #6
each
8
200-07765-0001
PARTS LIST, BRACKET SUPPORT, LEFT
each
1
200-07765-0003
PARTS LIST, BRACKET SUPPORT, RIGHT
each
1
200-07757-0001
PARTS LIST, BRACKET, MOUNTING
each
4
091-00477-0001
ISOLATION GROMMET
each
8
089-05931-0005
SCREW, BHP 6-32 X 5/16
each
8
089-06008-0004
SCREW, FHP 4-40 X 1/4
each
8
089-06008-0005
SCREW, FHP 4-40 X 5/16
each
28
076-01763-0000
BUSHING SHIELD 6-32
each
8
076-01764-0000
BUMPER TRAY .255
each
1
155-05659
INSTRUCTION SHEET, DUAL TRAY KIT
each
1
047-09832-0002
CABLE BRACKET ASSY
each
1
091-00109-0001
CABLE TIE .315
each
1
089-05903-0004
SCREW, PHP 4-40 X 1/4
each
2
156-041909-03
AVERY LABEL, MOUNTING TRAY, DUAL, 4 INCH,
NON-SAFETY WIRE COMPAIBLE
each
1
Page 1-8
Section 1 – General Information
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 1-11. VC-401B Mounting Tray Adapter Kit (050-02376-0000, Rev EB)
PART NUMBER
DESCRIPTION
U/M
QTY
155-05659
INSTRUCTION SHEET, DUAL TRAY KIT
each
1
047-07849-0003
GROUND STRAP
each
4
089-08485-0006
WASHER, EXTOOTH #6
each
8
200-07765-0001
PARTS LIST, BRACKET SUPPORT, LEFT
each
1
200-07765-0003
PARTS LIST, BRACKET SUPPORT, RIGHT
each
1
200-07757-0001
PARTS LIST, BRACKET, MOUNTING
each
4
091-00477-0001
ISOLATION GROMMET
each
8
089-05931-0005
SCREW, BHP 6-32 X 5/16
each
8
089-06008-0004
SCREW, FHP 4-40 X 1/4
each
8
089-06008-0005
SCREW, FHP 4-40 X 5/16
each
28
076-01763-0000
BUSHING SHIELD 6-32
each
8
076-01764-0000
BUMPER TRAY .255
each
1
047-09832-0002
CABLE BRACKET ASSY
each
1
091-00109-0001
CABLE TIE .315
each
1
089-05903-0004
SCREW, PHP 4-40 X 1/4
each
2
156-041926-01
LABEL, MOUNTING TRAY ADAPTER KIT, DUAL
each
1
When mounting two Control Units, use mounting adapter kits 071-01356-0000
(see Table 1-10) and 071-01356-0001 (see Table 1-11).
Table 1-12. CD-402B Mounting Adapter Kit Black (071-01356-0000, Rev. F)
PART NUMBER
DESCRIPTION
U/M
QTY
047-07783
ADAPTER, DZUS MOUNTING
RF
RF
047-07783-0002
BEZEL PAINTED BLK
each
1
092-00040-0000
PANEL FASTENER (DZUS)
each
4
156-041940-01
LABEL, DZUS MOUNTING ADAPTER KIT, BLACK,
CD
each
1
Table 1-13. CD-402B Mounting Adapter Kit Gray (071-01356-0001, Rev. F)
PART NUMBER
DESCRIPTION
U/M
QTY
047-07783
ADAPTER, DZUS MOUNTING
RF
RF
047-07783-0003
BEZEL PAINTED GRY
each
1
092-00040-0000
PANEL FASTENER (DZUS)
each
4
156-041945-01
LABEL, DZUS MOUNTING ADAPTER KIT, GREY,
CD
each
1
Publication No. 150-040984
Rev. K
Page 1-9
Section 1 – General Information
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Accessories Required But Not Supplied
7.
Microphone with a minimum output level of 250 mV.
8.
•
Headphone or speaker that accepts output rated at 2.4 Vrms into a 600 ohm impedance.
•
VHF Broadband Antenna with 50 Ω coaxial cable. VSWR 3:1 maximum.
•
Coaxial connectors and interwiring harness.
Tools Required But Not Supplied
A special crimping tool, positioner and an insertion/extraction tool are needed when the VCS 40A
VHF Communications System is installed. These tools and their part numbers (P/N) are listed
below.
9.
CRIMPING TOOL
POSITIONER
INSERTION/EXTRACTION TOOL
MIL M22520/2-01
MIL M22520/2-23
AMP P/N 91066-1
License Requirements
Check in the country of operation with the governing body for any licensing requirements. The
end user is responsible for obtaining any required licenses.
This equipment has been type accepted by the FCC under type acceptance number
FRWVC-401B.
Page 1-10
Section 1 – General Information
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
SECTION 2 – INSTALLATION
1.
General
This section contains suggestions and factors to consider before installing the VC-401B and the
CD-402B. Close adherence to these suggestions will assure a more satisfactory performance
from the equipment.
2.
Unpacking and Inspecting Equipment
Exercise extreme care when unpacking the equipment. Make a visual inspection of the units for
evidence of damage incurred during shipment. If a claim for damage is to be made, save the
shipping container to substantiate the claim. The claim should be promptly filed with the
transportation company. It would be advisable to retain the container and packaging material after
all equipment has been removed in the event that equipment storage or reshipment should
become necessary.
3.
Equipment Installation
The VCS 40A installation will conform to standards designated by the customer, installing
agency, and existing conditions as to the unit location and type of installation. See Figure 2-1 for
an outline drawing of the equipment. Before beginning installation the installing agency should
review the drawings, electrical interwiring diagram and installation pictorials which are located in
this section, and establish requirements to a particular aircraft.
A. Cooling Considerations
The greatest single contributor to increased reliability of all modern day avionics is limiting the
maximum operating temperature of the individual units, whether panel-mounted or remotemounted. While modern day circuit designs consume far less electrical energy, the watts per
cubic inch dissipated within the avionics units still remains much the same due to high density
packaging techniques utilized. Consequently, the importance of providing avionics cooling is
essential to the life span of the unit.
While each individual unit may or may not require forced air cooling, the combined heat load
of several units operating in a typical avionics location will significantly degrade the reliability
of the avionics if provisions for cooling are not incorporated in the initial installation. Failure to
provide cooling will certainly lead to increased avionics maintenance costs and may void the
Chelton warranty.
B. VC-401B Mechanical Installation
(1)
Select the VC-401B mounting location. The location should be free from excessive
moisture, vibration, heat and noise generating sources. The unit can be rigidly
mounted. Allow at least one inch of free air space around the top and rear of the unit
and one-half inch along each side. Allow adequate space for installation of cables
and connectors.
(2)
Refer to Figure 2-2 for the VC-401B mounting dimensions.
Publication No. 150-040984
Rev. K
Page 2-1
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
(3)
Mark, punch, and drill the mounting holes. Care must be taken to avoid damage to
adjacent equipment or cables.
(4)
Secure the mounting tray firmly in place.
(5)
Secure the VC-401B to the mounting tray.
C. Dual Installation Considerations
(1)
Reduction of cross radio interference by using Transmit Interlock feature.
All radio transceivers have a noise floor associated with the transmitted output signal.
When two or more radios are installed on the same aircraft, the transmitted noise floor
can cause the squelch of a radio operating in receive to open if care is not taken to
maximize the isolation between the antennas of the two systems. Isolation of greater
than 35 dB between the antennas should be a system design goal. However, due to the
size of the aircraft or limited locations for antenna mounting, it may not be possible to
obtain optimal antenna isolation or location.
In non-optimal situations, to reduce squelch opening during radio transmission, a
Transmit Interlock function, pin 86, is available to reduce the sensitivity of the affected
receiver when activated. The input for this function is open collector logic. To enable this
function, this pin should be pulled to ground during transmission of other radio systems.
On a dual radio system the Transmit Interlock function can be implemented by the
addition of two lines connecting the desired push-to-talk (PTT) lines and the Transmit
Interlock pins as follows:
VC-401B System #1
VC-401B System #2
P100
MIC _ LOW / PTT , pin 80
P100
to
TX _ INTERLOCK , pin 86
to
MIC _ LOW / PTT , pin 80
and
TX _ INTERLOCK , pin 86
It is important to notice that MIC _ LOW / PTT is the audio return line as well as a PTT
input for the radio. This input is designed for carbon microphones that combine the
microphone bias and the PTT function.
For three (3) VC-401B installations six external diodes can be used to interconnect the
PTT inputs to the Transmit Interlock inputs. The circuit for this interconnection is shown
in Figure 2-1.
Page 2-2
Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Figure 2-1. Three Radio System Transmit Interlock Wiring
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Rev. K
Page 2-3
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Mar 2007
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INSTALLATION MANUAL
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Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Publication No. 150-040984
Rev. K
Page 2-5
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Remove this page and insert 154-04047, Sheet 1 of 2 (Fig. 2-3a).
Publication No. 150-040984
Rev. K
Page 2-7
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Remove this page and insert 154-04047, Sheet 2 of 2 (Fig. 2-3b).
Publication No. 150-040984
Rev. K
Page 2-9
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Page 2-10
Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
D. VC-401B Harness and Connector Assembly
(1)
The installing agency will supply and fabricate all external cables. The connectors
and hardware required are supplied in the Chelton installation kits listed in
Section 1. Figure 2-4 illustrates the specific aspects of assembling the RF connector
and the wiring connector housing. Assembly details for the antenna end is
dependent on the antenna selected by the installer.
Figure 2-4. RF Cable Fabrication
(2)
The length and routing of the external cables must be carefully studied and planned
before attempting actual installation. Avoid sharp bends, placing the cables too near
the aircraft control cables, and routing adjacent to other aircraft harnessing and
cables that may cause interference or cross-talk.
(3)
Use only recommended wire sizes and wire type for interconnect. Wire sizes and
wire type are listed on the interconnect diagrams.
(4)
Use Figures 2-5 and 2-6 to become familiar with the connectors and pin locations on
the plugs for the fabrication of the external cables.
(5)
System interconnect diagram Figure 2-7 identifies those wires that must be shielded
or twisted.
(6)
Connect the external wiring to the VC-401B and associated equipment using the
appropriate interconnect drawings.
(7)
The VCS 40A system can be used with a radio management system or a Comm
Control Display. Refer to interconnect drawing Figure 2-7 for this type of installation.
(8)
Maximum length for +28 Vdc and DC PWR GND is 10 feet when using the specified
wire. When longer runs are required, increase the wire size to limit power lead
resistance to 0.050 ohm.
Publication No. 150-040984
Rev. K
Page 2-11
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Figure 2-5. VC-401B Rack Mount Connector
Page 2-12
Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 2-1. VC-401B Pin-outs
PIN
DESCRIPTION
PIN
DESCRIPTION
1
D-DATA
28
+10VDC
2
NOT USED
29
NOT USED
3
+28V IN
30
429 SHIELD
4
NOT USED
32
SPARE
5
POWER RETURN
33
NOT USED
6
NOT USED
34
SPARE
7
POWER RETURN
36
SPARE
8
NOT USED
38
DATA IN LO
9
DATA OUT HI
39
NOT USED
10
NOT USED
40
NOT USED
11
DATA OUT LO
41
DATA KEY
12
NOT USED
44
SAPRE
13
D-CLOCK
45
RS232 RX
14
NOT USED
46
RS232 TX
15
+28V IN
47
COMP DISABLE
16
NOT USED
48
8.33 ENABLE
17
CDU GROUND
50
SPARE
18
NOT USED
51
_ARINC IN 2A
19
AIRCRAFT GROUND
54
SDI BIT 10
20
NOT USED
55
GRAY CODE 2B
21
SPARE
56
TRANSFER
23
AGC
57
SPARE
24
NOT USED
58
SPARE
25
DATA IN HI
59
SPARE
26
D-ENAB
60
MIC INPUT
27
NOT USED
61
SPARE
continues…
Publication No. 150-040984
Rev. K
Page 2-13
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 2-1. VC-401B Pin-outs (cont’d)
PIN
DESCRIPTION
PIN
DESCRIPTION
62
AUDIO OUT HI
87
NOT USED
63
NOT USED
88
AUDIO OUT LO
64
VOICE/DATA
89
NOT USED
65
NOT USED
90
_ARINC OUT B
66
_ARINC IN 1B
91
NOT USED
67
GRAY CODE 1B
92
_ARINC IN 2B
68
NOT USED
93
NOT USED
69
AUDIO SHIELD
94
NOT USED
70
NOT USED
95
SDI BIT 9
71
SBY/ACT
96
NOT USED
72
NOT USED
97
GRAY CODE 1A
74
NOT USED
98
NOT USED
75
_ARINC OUT A
99
GRAY CODE 2A
76
NOT USED
100
NOT USED
77
SIDE TONE OUT LO
101
SQUELCH DISABLE
78
NOT USED
102
NOT USED
79
_ARINC IN 1A
103
SIDETONE_STRAP
80
MIC_LO/ PTT
104
NOT USED
82
GND
105
SIDETONE OUT HI
84
PS ENABLE
106
NOT USED
86
TX INTERLOCK
Page 2-14
Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Figure 2-6. VC-401B Polarizing Post Assembly
Publication No. 150-040984
Rev. K
Page 2-15
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Remove this page and insert 155-05747-0000, Sheet 1 of 1 (Fig. 2-7).
Publication No. 150-040984
Rev. K
Page 2-17
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
E. CD-402B Mechanical Installation
(1)
The installing agency will supply and fabricate all external cables. The connectors
and hardware required are supplied in the Chelton installation kits listed in
Section 1. Refer to Figure 2-8 for connector assembly.
Figure 2-8. CD-402B Cable Connector Assembly
(2) Select the CD-402B location. Ensure that the unit will be easily accessible and
clearly visible to the pilot.
(3)
For mounting dimensions, refer to Figure 2-9. Punch and drill the necessary
mounting holes.
(4)
The dichroic display of the CD-402B requires a heater voltage of +28 Vdc. The
heater draws 40 mA of current when operating in very cold environments.
Publication No. 150-040984
Rev. K
Page 2-19
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Table 2-2. CD-402B Pin-outs
Page 2-20
Section 2 - Installation
Mar 2007
PIN
DESCRIPTION
1
AUDIO HI
2
RESERVED
3
TST
4
KEY
5
8.33 ENABLE
6
RESERVED
7
GC 1B
8
+28 VDC PNL DIM BUS
9
+5 VDC/AC PNL DIM BUS
10
AUDIO LO
11
+10 VDC
12
5/28 V BACKLIGHTING
13
28 V HEATER
14
P/S ENABLE
15
GC 1A
16
GC 2B
17
GC 2A
18
AUDIO OUT
19
XFR
20
DISPLAY ENABLE
21
RESERVED
22
DISPLAY DATA
23
RESERVED
24
DISPLAY
25
CDU GND
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
Remove this page and insert 300-04231-0000, Sheet 1 of 1 (Fig. 2-9).
Publication No. 150-040984
Rev. K
Page 2-21
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Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Mar 2007
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Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
F. Antenna Installation
(1)
Locate the antenna according to the manufacturer’s instructions for the antenna
being used.
(2)
Mount the antenna on a flat metal surface to obtain a proper ground plane. Ensure
the antenna is adequately grounded to the aircraft skin. A doubler plate may be
required to support the antenna if the aircraft skin thickness does not provide
sufficient rigidity.
(3)
When other avionics and/or more than one VCS 40A system is to be installed, it is
necessary to provide adequate space isolation between the antennas of each
system to ensure that the use of one transceiver does not interfere with the
reception of the other system.
Note:
A minimum of 35 dB (3.5 feet) space isolation should be provided. Any steps
that can be taken to provide further isolation should be considered.
G. Optional Strapping
If more than one VCS 40A system is to be installed, each system must be identified as “COM
1”, “COM 2” or “COM 3”. This will help the installer when fabricating each system’s multiwire
cable harness because of the optional strapping required.
The VCS 40A provides for various wire strapping options (see Table 2-3). All strapping
options are connected in the wiring harness. Do not open units for wiring strapping.
Without strapping, the VCS 40A system is standby frequency tuned, has a blank system
number display, has no remote transfer of active and standby frequencies, and the sidetone
output is routed to the headphone via the auxiliary aircraft audio system.
Table 2-3. Strapping Options
Optional Function
Active Frequency Tuning
System Number “1”
System Number “2”
System Number “3”
Remote Transfer Function
(Panel or Yoke Mounted)
Sidetone Output through ”COMM AUDIO
OUT”
Publication No. 150-040984
Rev. K
Strap (VC-401B)
P1001-71 to ground
P1001-54 to ground
P1001-95 to ground
P1001-95 and P1001-54 ungrounded
P1001-56 or P1002-19 to one terminal of a
momentary SPST pushbutton switch. Remaining
switch terminal is connected to ground.
P1001-103 to ground
Page 2-23
Section 2 – Installation
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
4.
Post-Installation Check
Check the physical condition of the units, cables, connectors and the areas around the
installations. Check to see that all mounts are secure. Check to see that all cable connections are
secure.
A. System Test
(1)
Apply ground power to the aircraft. If ground power is not available, testing should
be performed with aircraft engine(s) running.
(2)
Apply power to the VCS 40A system. No warm-up period is required. System
operation is instantaneous upon application of power.
(3)
Set the CD-402B COM Control Display function selector to the “ON” position. The
CD-402B displays the last active (ACT) and standby frequencies of the VC-401B
VHF Communications Transceiver.
(4)
Tune the VCS 40A system to the local tower or ground control frequency.
Note:
(5)
If the system is set up for standby frequency tuning, momentarily depress the
frequency transfer pushbutton so that the desired frequency is displayed in the
active (ACT) frequency display.
Key the transmitter of the VC-401B. Each time the push-to-talk button is depressed,
the CD-402B transmit annunciator (Tx) is displayed. Request a radio check, and
release the push-to-talk button. VSWR should be checked at this time.
B. Flight Check
A flight test is recommended after the installation is completed to ensure satisfactory
performance of the equipment in its normal environment. Check all aircraft control
movements to be sure no electrical cables interfere with their operation. To check the
communications transceiver, maintain an appropriate altitude and contact a ground station
facility at a range of at least fifty nautical miles. Contact a ground station close in. If possible,
verify the communications capability on both the high and low end of the VHF Comm band.
Page 2-24
Section 2 - Installation
Mar 2007
Publication No. 150-040984
Rev. K
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
SECTION 3 – OPERATION
1.
General
Refer to Pilot’s Guide Series III, Publication No. 150-041074.
Publication No. 150-040984
Rev. K
Page 3-1
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Jun 2006
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INSTALLATION MANUAL
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VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
APPENDIX A - PRODUCT CROSS REFERENCE
This document is a Series III TSO’d product cross reference between Allied Signal company business
system numbers for products sold to Wulfsberg Electronics Division and the Wulfsberg Electronics
Division associated numbers to refer to the same product models.
The “CONTRACT MODEL” and “CONTRACT PN” appear in the AlliedSignal, Inc./Chelton Avionics, Inc.
Series III/FF VI Purchase Agreement dated March 17,1999. The “TSO MODEL” and “TSO PN” appear
on the FAA TSO letters and TSO labels. The “SYSTEM” refers to the certified system that the model
components belong to. The “WED DOC” is the Wulfsberg Electronics Division document that is the top
level design data for the respective models. The “BPN” is a Bendix company number that the models
used to be identified by and that some customers require to remain on the label to ease installation and
fleet operations. The “AKA1” is also an older Bendix company number that may be used.
SYSTEM
CONTRACT
MODEL
TSO
MODEL
CONTRACT
PN
TSO PN
WED DOC.
BPN
VCS 40A
CD 0402B
VCS 40A
CD-402B
071-01341-0000
071-1341-00
071-01341-0000
8095259-4001
CD 0402B
CD-402B
071-01341-0002
071-1341-02
071-01341-0002
8095259-4003
VCS 40A
CD 0402B
CD-402B
071-01341-0007
071-1341-07
071-01341-0007
8095259-4008
VCS 40A
VC 0401B
VC-401B
064-01047-0001
064-1047-01
064-01047-0001
3614001-4002
VCS 40A
VC 0401B
VC-401B
064-01047-0002
064-1047-02
064-01047-0002
3614001-4003
VCS 40A
VC 0401B
VC-401B
064-01047-0010
064-1047-10
064-01047-0010
3614001-4011
VCS 40A
VC 0401B
VC-401B
064-01047-0022
064-1047-22
064-01047-0022
3614001-4023
VCS 40A
VC 0401B
VC-401B
064-01047-0032
064-1047-32
064-01047-0032
3614001-4033
Publication No. 150-040984
Rev. K
AKA1
Page A-1
Appendix A
Mar 2007
VCS 40A VHF COMMUNICATION SYSTEM
INSTALLATION MANUAL
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Appendix A
Mar 2007
Publication No. 150-040984
Rev. K
Figure 2-2. VC-401B Outline Drawing (Sheet 1 of 1) (Dwg. No. 154-01047, Rev G)
Publication No. 150-040984
Section 2 - Installation
Figure 2-3a. Mounting Tray Envelope Drawing, 4-inch Single Mount (Sheet 1 of 2) (Dwg. No. 154-04047, Rev C)
Publication No. 150-040984
Section 2 - Installation
Figure 2-3b. Mounting Tray Envelope Drawing, 4-inch Dual Mount (Sheet 2 of 2) (Dwg No. 154-04047, Rev C)
Publication No. 150-040984
Section 2 - Installation
Figure 2-7.
VCS 40A Interconnect Diagram (Sheet 1 of 1) (Dwg. No. 155-05747-0000, Rev. J)
Publication No. 150-040984
Section 2 - Installation
Figure 2-9.
CD-402B Outline Drawing (Sheet 1 of 1) (Dwg No. 300-04231-0000, Rev J)
Publication No. 150-040984
Section 2 - Installation