Aeroflex ATC-601-2 User manual

Ramp Test Set
Maintenance Manual
1002-8106-4P0
ATC-601-2
Issue-2

MAINTENANCE MANUAL
RAMP TEST SET
ATC-601-2
PUBLISHED BY
Aeroflex
COPYRIGHT ©Aeroflex 2007
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or
otherwise without the prior permission of the publisher.
Original Printing Jul 2002
Issue-2 Jan 2007
10200 West York / Wichita, Kansas 67215 U.S.A. / [phone] / FAX [phone]

MAINTENANCE MANUAL
ATC-601-2
FOR QUALIFIED SERVICE
PERSONNEL ONLY

MAINTENANCE MANUAL
ATC-601-2
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MAINTENANCE MANUAL
ATC-601-2
Nomenclature Statement:
In this manual Test Set or Unit refers to the ATC-601-2 Ramp Test Set.
Cable Statement:
For continued EMC compliance, all external cables must be 3 meters or less in length.

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ATC-601-2
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MAINTENANCE MANUAL
ATC-601-2
WARNING:
HIGH VOLTAGE EQUIPMENT
THIS EQUIPMENT CONTAINS CERTAIN CIRCUITS AND/OR COMPONENTS
OF EXTREMELY HIGH VOLTAGE POTENTIALS, CAPABLE OF CAUSING
SERIOUS BODILY INJURY OR DEATH. WHEN PERFORMING ANY OF THE
PROCEDURES CONTAINED IN THIS MANUAL, HEED ALL APPLICABLE
SAFETY PRECAUTIONS.
SAFETY FIRST: TO ALL OPERATIONS AND SERVICE PERSONNEL
REFER ALL SERVICING OF UNIT TO QUALIFIED TECHNICAL PERSONNEL.
WARNING: USING THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY THE ACCOMPANYING
DOCUMENTATION MAY IMPAIR THE SAFETY PROTECTION PROVIDED BY THE EQUIPMENT.
CASE, COVER OR PANEL REMOVAL
Removing protective covers, casings or panels from this Test Set exposes the technician to electrical
hazards that can result in electrical shock or equipment damage.
SAFETY IDENTIFICATION IN TECHNICAL MANUAL
This manual uses the following terms to draw attention to possible safety hazards, that may exist when
operating or servicing this equipment.
CAUTION: THIS TERM IDENTIFIES CONDITIONS OR ACTIVITIES THAT, IF IGNORED, CAN RESULT IN
EQUIPMENT OR PROPERTY DAMAGE (E.G., FIRE).
WARNING: THIS TERM IDENTIFIES CONDITIONS OR ACTIVITIES THAT, IF IGNORED, CAN RESULT IN
PERSONAL INJURY OR DEATH.
SAFETY SYMBOLS IN MANUALS AND ON UNITS
CAUTION: Refer to accompanying documents. (This symbol refers to specific CAUTIONS
represented on the unit and clarified in the text.)
AC OR DC TERMINAL: Terminal that may supply or be supplied with ac or dc voltage.
DC TERMINAL: Terminal that may supply or be supplied with dc voltage.
AC TERMINAL: Terminal that may supply or be supplied with ac or alternating voltage.
SWITCH OFF: AC line power to the device is OFF.
SWITCH ON: AC line power to the device is ON.
EQUIPMENT GROUNDING PRECAUTION
Improper grounding of equipment can result in electrical shock.
USE OF PROBES
Check specifications for the maximum voltage, current and power ratings of any connector on the Test Set
before connecting it with a probe from a terminal device. Be sure the terminal device performs within these
specifications before using it for measurement, to prevent electrical shock or damage to the equipment.
POWER CORDS
Power cords must not be frayed, broken nor expose bare wiring when operating this equipment.

MAINTENANCE MANUAL
ATC-601-2
USE RECOMMENDED FUSES ONLY
Use only fuses specifically recommended for the equipment at the specified current and voltage ratings.
WARNING: THE ATC-601-2 USES A NICAD BATTERY. THE FOLLOWING WARNINGS CONCERNING
NICAD BATTERIES MUST BE HEEDED:
ODO NOT RECHARGE OUTSIDE THE ATC-601-2.
ODO NOT CRUSH, INCINERATE OR DISPOSE OF IN NORMAL WASTE.
ODO NOT SHORT CIRCUIT OR FORCE DISCHARGE AS THIS MIGHT CAUSE THE BATTERY
TO VENT, OVERHEAT OR EXPLODE.
CAUTION: INTEGRATED CIRCUITS AND SOLID STATE DEVICES SUCH AS MOS FETS, ESPECIALLY
CMOS TYPES, ARE SUSCEPTIBLE TO DAMAGE BY ELECTROSTATIC DISCHARGES RECEIVED
FROM IMPROPER HANDLING, THE USE OF UNGROUNDED TOOLS AND IMPROPER STORAGE
AND PACKAGING. ANY MAINTENANCE TO THIS UNIT MUST BE PERFORMED WITH THE
FOLLOWING PRECAUTIONS:
OBEFORE USE IN A CIRCUIT, KEEP ALL LEADS SHORTED TOGETHER EITHER BY THE USE
OF VENDOR-SUPPLIED SHORTING SPRINGS OR BY INSERTING LEADS INTO A
CONDUCTIVE MATERIAL.
OWHEN REMOVING DEVICES FROM THEIR CONTAINERS, GROUND THE HAND BEING USED
WITH A CONDUCTIVE WRISTBAND.
OTIPS OF SOLDERING IRONS AND/OR ANY TOOLS USED MUST BE GROUNDED.
ODEVICES MUST NEVER BE INSERTED INTO NOR REMOVED FROM CIRCUITS WITH
POWER ON.
OPC BOARDS, WHEN TAKEN OUT OF THE SET, MUST BE LAID ON A GROUNDED
CONDUCTIVE MAT OR STORED IN A CONDUCTIVE STORAGE BAG. REMOVE ANY BUILT-
IN POWER SOURCE, SUCH AS A BATTERY, BEFORE LAYING PC BOARDS ON A
CONDUCTIVE MAT OR STORING IN A CONDUCTIVE BAG.
OPC BOARDS, IF BEING SHIPPED TO THE FACTORY FOR REPAIR, MUST BE PACKAGED IN
A CONDUCTIVE BAG AND PLACED IN A WELL-CUSHIONED SHIPPING CONTAINER.
CAUTION
THIS EQUIPMENT CONTAINS PARTS
SENSITIVE TO DAMAGE
BY ELECTROSTATIC DISCHARGE (ESD)
CAUTION: SIGNAL GENERATORS CAN BE A SOURCE OF ELECTROMAGNETIC INTERFERENCE (EMI) TO
COMMUNICATION RECEIVERS. SOME TRANSMITTED SIGNALS CAN CAUSE DISRUPTION
AND INTERFERENCE TO COMMUNICATION SERVICES OUT TO A DISTANCE OF SEVERAL
MILES. USERS OF THIS EQUIPMENT SHOULD SCRUTINIZE ANY OPERATION THAT RESULTS
IN RADIATION OF A SIGNAL (DIRECTLY OR INDIRECTLY) AND ENSURE COMPLIANCE WITH
INSTRUCTIONS IN FAA CIRCULAR AC 170-6C, DATED FEBRUARY 19, 1981.
CAUTION: KEEP ALL VENT OPENINGS CLEAR AND UNOBSTRUCTED FOR PROPER EQUIPMENT COOLING
AND CONTINUED RELIABILITY. WHEN OPERATING THE EQUIPMENT IN THE NORMAL
HORIZONTAL POSITION, MAINTAIN AT LEAST TWO INCHES (≈FIVE CENTIMETERS) OF
CLEARANCE BETWEEN THE EQUIPMENT SIDE WITH EXHAUST FAN AND OBJECTS OR WALLS.
IF OPERATING IN A RACK, MAXIMUM AMBIENT TEMPERATURE MUST BE AT OR BELOW 40°C.

MAINTENANCE MANUAL
ATC-601-2
TABLE OF CONTENTS
Page 1
Jan 1/07
TABLE OF CONTENTS
Title Chapter/Section
Title Page
Copyright Page
For Qualified Personnel Only Page
Statements
Warning/Cautions Pages
Table of Contents
Introduction
Chapter 2
Section 1 - Servicing 2-1
Section 2 - Troubleshooting 2-2
Section 3 - Disassembly/Reassembly 2-3
Section 4 - ATC-601-2 Parts List 2-4
Appendix A - Connector Pin-Out Tables
Appendix B - Test Equipment Requirements
Appendix C - PAL Equations
Appendix D - Timing Diagrams
Appendix E - Metric/British Imperial Conversion Table with Nautical Distance Conversions
Appendix F - Specifications
Appendix G - Controls, Connectors and Indicators
Appendix H - Abbreviations
Index

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MAINTENANCE MANUAL
ATC-601-2
INTRODUCTION
Page 1
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INTRODUCTION
This manual contains the information necessary to test and repair the ATC-601-2 Ramp Test Set.
It is strongly recommended that personnel be thoroughly familiar with the contents of this manual
before attempting to perform maintenance on this equipment.
Only qualified personnel should perform maintenance on this equipment.
ORGANIZATION
This manual is divided into the following sections:
CHAPTER 2 - MAINTENANCE
Section 1 - SERVICING (preventive maintenance)
Section 2 - TROUBLESHOOTING (theory of operation, calibration/verification,
assemblies and schematics)
Section 3 - DISASSEMBLY / REASSEMBLY
Section 4 - ATC-601-2 PARTS LIST

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ATC-601-2
INTRODUCTION
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MAINTENANCE MANUAL
ATC-601-2
2-TABLE OF CONTENTS
Page 1
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CHAPTER TWO
ATC-601-2 RAMP TEST SET
MAINTENANCE MANUAL
TABLE OF CONTENTS
Title Chapter/Section/Subject Page
SECTION 1 - SERVICING 2-1
1. Preventive Maintenance Procedures 2-1-1 1
A. External Cleaning 2-1-1 1
B. Internal Cleaning 2-1-1 1
C. Visual Inspection 2-1-1 2
SECTION 2 - TROUBLESHOOTING 2-2
1. Theory of Operation 2-2-1 1
A. General 2-2-1 1
B. System Theory of Operation 2-2-1 1
C. Functional Theory of Operation 2-2-1 1
(1) Transmit 2-2-1 1
(2) Receive 2-2-1 3
(3) Testing 2-2-1 3
D. Module Theory of Operation 2-2-1 10
(1) Power Supply 2-2-1 10
(2) Digital IF PC Board Assembly 2-2-1 15
(3) Front Panel Pulse PC Board Assembly 2-2-1 21
(4) RF Assembly 2-2-1 39
(5) Front Panel Assembly 2-2-1 51
2. Calibration/Verification 2-2-2 1
A. General 2-2-2 1
(1) Calibration/Verification Schedule 2-2-2 2
(2) Controls, Connectors and Indicators 2-2-2 2
(3) Test Record 2-2-2 2
B. Precautions 2-2-2 5
(1) Safety 2-2-2 5
(2) ESD 2-2-2 5
(3) EMC and Safety Compliance 2-2-2 5
C. Requirements 2-2-2 6
(1) Performance 2-2-2 6
(2) Test Equipment 2-2-2 6
(3) Disassembly 2-2-2 6
(4) Environment 2-2-2 6
D. Verification Procedures 2-2-2 7
(1) Signal Generator 2-2-2 7
(2) Pulse Characteristics 2-2-2 9
(3) UUT Measurements 2-2-2 18
(4) Overall 2-2-2 30
E. Verification Data Sheet 2-2-2 27
F. Calibration Procedures 2-2-2 33
(1) Power Supply 2-2-2 33
(2) RF Assembly 2-2-2 34
(3) System 2-2-2 44
G. Calibration Data Sheet 2-2-2 47

MAINTENANCE MANUAL
ATC-601-2
2-TABLE OF CONTENTS
Page 2
Jan 1/07
TABLE OF CONTENTS (cont)
Title Chapter/Section/Subject Page
SECTION 2 - TROUBLESHOOTING (cont)
3. Assemblies and Schematics 2-2-3 1
A. General 2-2-3 1
B. How to Use Schematics 2-2-3 1
(1) Coaxial Cables 2-2-3 1
(2) Multiple Pin Connectors 2-2-3 1
C. Alphabetical Index of Assemblies and Schematics 2-2-3 2
SECTION 3 - DISASSEMBLY/REASSEMBLY 2-3
1. Disassembly 2-3-1 1
A. General 2-3-1 1
B. Preliminary Considerations 2-3-1 1
(1) Tools Required 2-3-1 1
(2) Disassembly Precautions 2-3-1 1
(3) ESD 2-3-1 2
(4) EMC and Safety Compliance 2-3-1 2
C. Procedures 2-3-1 4
(1) Storage Compartment and Chassis Assembly 2-3-1 4
(2) Battery 2-3-1 7
(3) Line Supply Assembly 2-3-1 7
(4) Power Supply Assembly 2-3-1 9
(5) Digital IF PC Board Assembly 2-3-1 11
(6) Front Panel Pulse PC Board Assembly 2-3-1 11
(7) RF Assembly 2-3-1 13
(8) Front Panel Assembly 2-3-1 21
(9) Flat Antenna Assembly 2-3-1 28
(10) Motherboard PC Board Assembly 2-3-1 30
2. Reassembly 2-3-2 1
A. General 2-3-1 1
B. Preliminary Considerations 2-3-2 1
(1) Tools Required 2-3-2 1
(2) Reassembly Precautions 2-3-2 1
(3) ESD 2-3-2 2
(4) EMC and Safety Compliance 2-3-2 2
C. Special Reassembly Procedures 2-3-2 2
(1) Storage Compartment and Chassis Assembly 2-3-2 2
(2) Battery 2-3-2 2
(3) Line Supply Assembly 2-3-2 3
(4) Power Supply Assembly 2-3-2 3
(5) Digital IF PC Board Assembly 2-3-2 3
(6) Front Panel Pulse PC Board Assembly 2-3-2 3
(7) RF Assembly 2-3-2 3
(8) Front Panel Assembly 2-3-2 4
(9) Flat Antenna Assembly 2-3-2 6
(10) Motherboard PC Board Assembly 2-3-2 6
SECTION 4 - ATC-601-2 PARTS LIST 2-4

MAINTENANCE MANUAL
ATC-601-2
2-LIST OF ILLUSTRATIONS
Page 1
Jan 1/07
LIST OF ILLUSTRATIONS
Title Chapter/Section/Subject Page
System Block Diagram 2-2-1 2
Power Supply Assembly Block Diagram 2-2-1 13
Digital IF PC Board Assembly Block Diagram 2-2-1 14
Clock Format Timing Diagram 2-2-1 16
Pulse Generator Data Transfer Timing Diagram 2-2-1 24
500 kHz Clock Timing Diagram 2-2-1 29
Front Panel Pulse PC Board Assembly Block Diagram 2-2-1 37
RF Assembly Block Diagram 2-2-1 38
Attenuator PC Board Assembly Block Diagram 2-2-1 39
LO Source PC Board Assembly Block Diagram 2-2-1 40
Mixer PC Board Assembly Block Diagram 2-2-1 41
Driver PC Board Assembly Block Diagram 2-2-1 43
Detector Assembly Block Diagram 2-2-1 45
Trailing Edge Comparator Input Signals 2-2-1 47
Leading Edge Comparator Input Signals 2-2-1 47
Detector Comparator Pulses 2-2-1 47
Analog IF Assembly Block Diagram 2-2-1 48
Pulse Characteristics Test Setup Diagram 2-2-2 9
P1to SPR Spacing/Phase Transition Time 2-2-2 10
Frequency Measurement Test Setup Diagram 2-2-2 13
UUT Transmitter Frequency Modulation Signal 2-2-2 14
Replay Delay Test Setup Diagram 2-2-2 16
Reply Jitter Test Setup Diagram 2-2-2 21
Test Points and Adjustments 2-2-2 32
Attenuator VSWR Test Setup Diagram 2-2-2 36
Attenuator Test Setup Diagram 2-2-2 37
Receive Image Test Setup Diagram 2-2-2 39
Detector Pulse Width Test Setup Diagram 2-2-2 40
Direct Connect Set Test Setup Diagram 2-2-2 41
Composite Assembly 2-2-3 3
Power Supply Assembly 2-2-3 5
Line Supply Assembly 2-2-3 9
Motherboard PC Board Assembly 2-2-3 11
Digital IF PC Board Assembly 2-2-3 13
Flat Antenna Assembly 2-2-3 16
Front Panel Pulse PC Board Assembly 2-2-3 18
RF Assembly 2-2-3 30
Front Panel Assembly 2-2-3 49
ATC-601 Chassis and Storage Compartment Disassembly 2-3-1 5
ATC-601-2 Test Set Rear View 2-3-1 6
Line Supply Disassembly 2-3-1 8
Power Supply Disassembly 2-3-1 10
RF Disassembly 2-3-1 12
Detector Disassembly 2-3-1 14
Analog IF Disassembly 2-3-1 17
SSB Disassembly 2-3-1 18
ATC-601-2 Test Set Top View 2-3-1 21
Front Panel Disassembly 2-3-1 23
Power Termination Disassembly 2-3-1 26
Flat Antenna Disassembly 2-3-1 29
Mixer PC Board Assembly 2-3-2 5
Solder Points for Backlight Wire Harness 2-3-2 6
Flat Antenna Assembly 2-3-2 7

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ATC-601-2
2-LIST OF ILLUSTRATIONS
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ATC-601-2
2-LIST OF TABLES
Page 1
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LIST OF TABLES
Title Chapter/Section/Subject Page
Self Test 2-2-1 6
Digitizer PAL Inputs and Outputs 2-2-1 17
Microprocessor U27001 Chip Selects 2-2-1 21
Pulse Generator Serialized Data Output 2-2-1 24
Reply Decoder Control Register Bit Definition 2-2-1 27
Reply Data Byte Information 2-2-1 29
Keypad Data Definition 2-2-1 31
Attenuator #2 Operation Selection 2-2-1 32
Analog Input to ADC Description 2-2-1 33
Status Buffer Bit Definition 2-2-1 34
LED Control Register Bit Definition 2-2-1 35
DPSK Modulation 2-2-1 44
Transmit Gain Settings 2-2-1 50
Assembly Replacement Calibration Requirements 2-2-2 3
Verification Failure Calibration Requirements 2-2-2 4
Output Level/UUT Receiver Sensitivity 2-2-2 8
Power Measurement Data 2-2-2 15
Mode S Reply 2-2-2 19
Oscillator Compensation 2-2-2 43
Disassembly Tools 2-3-1 1

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ATC-601-2
2-LIST OF TABLES
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ATC-601-2
2-1-1
Page 1
Jan 1/07
SECTION 1 - SERVICING
1. Preventive Maintenance Procedures
Contains routine maintenance instructions for cleaning and inspecting the Test Set.
CAUTION: DISCONNECT POWER FROM TEST SET TO AVOID POSSIBLE DAMAGE TO
ELECTRONIC CIRCUITS.
A. External Cleaning
STEP PROCEDURE
1. Clean front panel and display face with soft lint-free cloth. If dirt is difficult to
remove, dampen cloth with water and mild liquid detergent.
2. Remove grease, fungus and ground-in dirt from surfaces with soft lint-free cloth
dampened (not soaked) with isopropyl alcohol.
3. Remove dust and dirt from connectors with soft-bristled brush.
4. Cover connectors, not in use, with suitable dust cover to prevent tarnishing of
connector contacts.
5. Clean cables with soft lint-free cloth.
6. Paint exposed metal surface to avoid corrosion.
B. Internal Cleaning
CAUTION
THIS EQUIPMENT CONTAINS PARTS
SENSITIVE TO DAMAGE
BY ELECTROSTATIC DISCHARGE (ESD)
CAUTION: DO NOT MOVE COMPONENTS ON CIRCUIT BOARDS OR DISASSEMBLE
CONNECTORS NEEDLESSLY TO AVOID POSSIBLE DAMAGE.
CAUTION: DO NOT OPEN COMPLEX INTERNAL MODULES FOR SOLE PURPOSE OF
CLEANING AND INSPECTION.
Remove dust with hand-controlled dry air jet of 15 psi (1.054 kg/cm2) and wipe internal
chassis parts and frame with soft lint-free cloth moistened with isopropyl alcohol.

MAINTENANCE MANUAL
ATC-601-2
2-1-1
Page 2
Jan 1/07
C. Visual Inspection
STEP PROCEDURE
1. Inspect Chassis for:
OTightness of sub-assemblies and chassis mounted connectors.
OCorrosion or damage to metal surfaces.
2. Inspect Capacitors for:
OLoose mounting, deformities or obvious physical damage.
OLeakage or corrosion around leads.
3. Inspect Connectors for:
OLoose or broken parts, cracked insulation and bad contacts.
4. Inspect Circuit Boards for:
OCorrosion or damage to connectors.
ODamage to mounted components including crystals and ICs.
OFreedom from foreign material.
5. Inspect Resistors for:
OCracked, broken, charred or blistered bodies.
OLoose or corroded soldering connections.
6. Inspect Semiconductors for:
OCracked, broken, charred or discolored bodies.
OCorrect placement and condition of seals around leads.
7. Inspect Wiring for:
OBroken or loose ends and connections.
OProper dress relative to other chassis parts.
NOTE: Verify wrapped wiring is tight.