Aeroflex IFR 4000 User manual

NAV/COMM Test Set
Maintenance Manual
1002-5600-4P0
IFR 4000

MAINTENANCE MANUAL
NAV/COMM TEST SET
IFR 4000
PUBLISHED BY
Aeroflex
COPYRIGHT ©Aeroflex 2004
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.
10200 West York / Wichita, Kansas 67215 U.S.A. / [phone] / FAX [phone]

MAINTENANCE MANUAL
IFR 4000
FOR QUALIFIED SERVICE
PERSONNEL ONLY

MAINTENANCE MANUAL
IFR 4000
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MAINTENANCE MANUAL
IFR 4000
Cable Statements:
For continued EMC compliance, all external cables must be three meters or less in length.
For continued EMC compliance, all external cables must be double shielded.

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IFR 4000
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MAINTENANCE MANUAL
IFR 4000
SAFETY FIRST: TO ALL 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
Opening the Case Assembly exposes the operator to electrical hazards that can result in electrical shock or
equipment damage. Do not operate this Test Set with the Case Assembly open.
SAFETY IDENTIFICATION IN TECHNICAL MANUAL
This manual uses the following terms to draw attention to possible safety hazards that may exist when
operating 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.
DANGEROUS VOLTAGE: Indicates electrical shock hazard due to high voltage levels.
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.
USE RECOMMENDED FUSES ONLY
Use only fuses specifically recommended for the equipment at the specified current and voltage ratings.
WARNING: THE 4000 USES A LITHIUM ION BATTERY PACK. THE FOLLOWING WARNINGS
CONCERNING LITHIUM ION BATTERIES MUST BE HEEDED:
•DO NOT RECHARGE OUTSIDE THE IFR 4000.
•DO NOT CRUSH, INCINERATE OR DISPOSE OF IN NORMAL WASTE.
•DO NOT SHORT CIRCUIT OR FORCE DISCHARGE AS THIS MIGHT CAUSE THE BATTERY
TO VENT, OVERHEAT OR EXPLODE.

MAINTENANCE MANUAL
IFR 4000
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:
•BEFORE 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.
•WHEN REMOVING DEVICES FROM THEIR CONTAINERS, GROUND THE HAND BEING
USED WITH A CONDUCTIVE WRISTBAND.
•TIPS OF SOLDERING IRONS AND/OR ANY TOOLS USED MUST BE GROUNDED.
•DEVICES MUST NEVER BE INSERTED INTO NOR REMOVED FROM CIRCUITS WITH
POWER ON.
•PC 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.
•PC 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.

MAINTENANCE MANUAL
IFR 4000
TABLE OF CONTENTS
Page 1
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TABLE OF CONTENTS
Title Chapter/Section
Title Page
Copyright Page
For Qualified Service Personnel Only Page
Statements
Safety Page
Table of Contents
Introduction
Chapter 2
Section 1 - Servicing 2-1
Section 2 - Troubleshooting 2-2
Section 3 - Disassembly/Reassembly 2-3
Section 4 - Parts List 2-4
Appendix A - Connector Pin-Out Tables
Appendix B - Test Equipment Requirements
Appendix C - Metric/British Imperial Conversion Table with Nautical Distance Conversions
Appendix D - Specifications
Appendix E - Controls, Connectors and Indicators
Appendix F - Abbreviations
Index

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IFR 4000
TABLE OF CONTENTS
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MAINTENANCE MANUAL
IFR 4000
INTRODUCTION
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INTRODUCTION
This manual contains the information necessary to test and repair the IFR 4000.
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 Chapters and Sections:
CHAPTER 2 - MAINTENANCE
Section 1 - SERVICING (preventive maintenance)
Section 2 - TROUBLESHOOTING (theory of operation, troubleshooting procedures,
calibration/verification, assembly drawings)
Section 3 - DISASSEMBLY/REASSEMBLY
Section 4 - PARTS LIST

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IFR 4000
INTRODUCTION
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MAINTENANCE MANUAL
IFR 4000
2-TABLE OF CONTENTS
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CHAPTER TWO
IFR 4000 NAV/COMM 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. Power Supply Assy 2-2-1 1
B. Multi-Function PCB Assy 2-2-1 5
C. Processor PCB Assy 2-2-1 9
D. RF Assy 2-2-1 11
2. Troubleshooting Procedures 2-2-2 1
A. Guidelines 2-2-2 1
B. Precautions 2-2-3 2
(1) Safety 2-2-3 2
(2) ESD 2-2-3 2
(3) EMC and Safety Compliance 2-2-3 2
3. Calibration/Verification 2-2-3 1
A. General 2-2-3 1
(1) Calibration/Verification Schedule 2-2-3 2
(2) Controls, Connectors and Indicators 2-2-3 2
(3) Test Record 2-2-3 2
B. Precautions 2-2-3 2
C. Requirements 2-2-3 2
(1) Performance 2-2-3 2
(2) Test Equipment 2-2-3 2
(3) Disassembly 2-2-3 2
(4) Environment 2-2-3 2
D. Verification 2-2-3 3
(1) Self Test 2-2-3 3
(2) RF Accuracy 2-2-3 4
(3) RF Level Accuracy (ANT Connector) 2-2-3 7
(4) RF Level Flatness (ANT Connector) 2-2-3 9
(5) RF Level Accuracy (RF I/O Connector) 2-2-3 12
(6) RF Level Flatness (RF I/O Connector) 2-2-3 14
(7) Harmonic and Spurious 2-2-3 17
(8) VSWR (RF I/O and SWR Connectors) 2-2-3 19
(9) Marker Beacon 2-2-3 21
(10) VOR 2-2-3 22
(11) Localizer 2-2-3 25
(12) Glideslope 2-2-3 28
(13) ILS 2-2-3 30
(14) COMM VHF AM 2-2-3 33

MAINTENANCE MANUAL
IFR 4000
2-TABLE OF CONTENTS
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Title Chapter/Section/Subject Page
D. Verification (cont)
(15) COMM UHF 2-2-3 34
(16) Frequency Counter 2-2-3 35
(17) AM Meter 2-2-3 37
(18) FM Meter 2-2-3 39
(19) SWR Meter 2-2-3 41
(20) Power Meter 2-2-3 43
E. Verification Data Sheet 2-2-3 44
F. Calibration 2-2-3 57
(1) Test Setup 2-2-3 57
(2) Miscellaneous 2-2-3 59
(3) RF Amplitude Levels 2-2-3 61
(4) Modulation 2-2-3 63
4. Assembly Drawings 2-2-4 1
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 3
(1) Battery 2-3-1 3
(2) Fuse 2-3-1 5
(3) Case Assy 2-3-1 7
(4) Power Supply PCB Assy 2-3-1 9
(5) RF Assy 2-3-1 10
(6) Processor PCB Assy 2-3-1 12
(7) Multi-Function PCB Assy 2-3-1 13
(8) Keypad PCB Assy 2-3-1 15
(9) LCD PCB Assy 2-3-1 16
2. Reassembly 2-3-2 1
A. General 2-3-2 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 1
(4) EMC and Safety Compliance 2-3-2 1
C. Procedures 2-3-2 2
(1) Battery 2-3-2 2
(2) Fuse 2-3-2 2
(3) Case Assy 2-3-2 2
(4) Power Supply PCB Assy 2-3-2 2
(5) RF Assy 2-3-2 2
(6) Processor PCB Assy 2-3-2 2
(7) Multi-Function PCB Assy 2-3-2 2
(8) Keypad PCB Assy 2-3-2 2
(9) LCD PCB Assy 2-3-2 2
SECTION 4 - PARTS LIST 2-4

MAINTENANCE MANUAL
IFR 4000
2-LIST OF ILLUSTRATIONS/TABLES
Page 1
Aug 1/04
LIST OF ILLUSTRATIONS
Title Chapter/Section/Subject Page
Power Supply PCB Assy Block Diagram 2-2-1 3
Multi-Function PCB Assy Block Diagram 2-2-1 4
Processor PCB Assy Block Diagram 2-2-1 9
RF Assy Block Diagram 2-2-1 15
Troubleshooting Table 2-2-2 4
Power Meter Calibration Setup 2-2-3 58
Composite Assy 2-2-4 3
Power Supply PCB Assy 2-2-4 5
Chassis Assy 2-2-4 12
Keypad PCB Assy 2-2-4 13
Processor PCB Assy 2-2-4 15
Multi-Function PCB Assy 2-2-4 25
LCD Assy 2-2-4 37
RF Assy 2-2-4 38

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IFR 4000
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MAINTENANCE MANUAL
IFR 4000
2-1-1
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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
IFR 4000
2-1-1
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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.

MAINTENANCE MANUAL
IFR 4000
2-2-1
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SECTION 2 - TROUBLESHOOTING
1. Theory of Operation
A. Power Supply PCB Assy
The Power Supply PCB Assy is responsible for supplying power to the internal modules for
operation and for charging the internal batteries. The Power Supply PCB Assy operates
from externally supplied DC power and provides simultaneous run and battery charge, or
battery charge only. The battery charge time increases when in the run and charge mode.
The Power Supply Assy consists of a DC-DC Converter, ON/OFF Control circuitry and the
Battery Charger circuitry. The external DC input is supplied from an External DC Power
Supply (supplied).
The internal batteries are removable/replaceable Li Ion battery packs with an internal "gas-
gauge" feature that allows accurate determination of remaining battery life. Maximum
operating and storage temperature for Li Ion batteries is -20°C to +60°C and the maximum
charging temperature is 0°C to +45°C.
The Power Supply PCB Assy contains a synchronous buck converter to convert the input
voltage to a fixed output voltage (+10 Vdc). The Power Supply PCB Assy also contains a
low-pass filter to reduce the amount of internal emissions. The Input Converter Assembly is
capable of providing enough output current to charge the battery at full current and run the
Test Set at the same time, as long as the input voltage is within range.
(1) Battery Charger
The battery charger is a boost type converter. This battery charger monitors the
battery voltage and temperature to determine if the battery is capable of being
recharged, and if it is safe to attempt to recharge the battery. The battery must be at
least at a 9.2 V level and the temperature must be between 0°and 45°C before a
charge cycle initiates.
(2) Output Circuitry
The output converters are comprised of a dual-phase synchronous buck converter for
developing +3.3 and +5 V outputs. The converter also has an auxiliary output that is
used to generate +16 V from the +VS source (either the battery or input converter). A
separate buck/boost converter is used to generate the -5 V output. The primary
converter provides dual phase control, as well as gate drive for the switching mosfets
and over-current protection. The main converter runs at 220 kHz, while the auxiliary
converter runs at 1.2 MHz.
Both +3.3 and +5 V outputs are capable of delivering up to 3 A of current and the 16 V
output can deliver up to 80 mA. If any of these three outputs experience a severe
over-current, the supply turns OFF.
The -5 V converter is a stand-alone buck/boost converter that runs at approximately
220 kHz and can deliver up to 400 mA of current before starting to fold back. If the
supply experiences a severe over-current condition, the supply stays in fold-back mode
until the short is removed.

MAINTENANCE MANUAL
IFR 4000
2-2-1
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(3) Source Select Circuitry
The source select circuitry is designed to be a low-loss switch that selects the
appropriate source when the output of the ON/OFF circuitry is high. The external DC
(+Vdc) is selected if present. If external DC is not present, the battery (VBAT+)
connects to +VS. If the Test Set is running on external DC or Line Voltage, and that
power source is removed, the Test Set shuts OFF.
The second function of the switching circuitry is to prevent battery current from flowing
into the input converter section when the Test Set is running on battery power. A low
voltage cutoff is also incorporated into the ON/OFF circuitry.
(4) Protection Circuitry
The protection circuitry has four basic functions related to the DC input. The battery
has internal protection circuitry. The external DC input has a fuse, an over-voltage
crowbar and reverse protection diodes. The fuse is the primary disconnect to protect
against any of the fault conditions. If the DC input is too high (>32 V), the over-
voltage crowbar triggers and the SCR opens the fuse. If the DC input polarity is
incorrect, the input clamp diodes forward bias and open the fuse. If the input
converter fails and the output of the converter is above 12 V, the SCR triggers and
opens the fuse. If the DC input voltage is too low, the input converter is disabled until
the input voltage is within the allowable range.