Aeroflex TCAS-201-2 User manual

Ramp Test Set
Maintenance Manual
1002-8504-400
Issue-2
TCAS-201-2
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MAINTENANCE MANUAL
RAMP TEST SET
TCAS-201-2
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.
Original Printing Jul 1998
Revision 1 Dec 1998
Revision 2 Mar 1999
Issue-2 Sep 2004
10200 West York / Wichita, Kansas 67215 U.S.A. / [phone] / FAX [phone]
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MAINTENANCE MANUAL
TCAS-201-2
FOR QUALIFIED SERVICE
PERSONNEL ONLY
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TCAS-201-2
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MAINTENANCE MANUAL
TCAS-201-2
Cable Statements:
A double shielded and properly terminated external interface cable must be used with this
equipment when interfacing with the COMM Connector.
For continued EMC compliance, all external cables must be 3 meters or less in length.
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TCAS-201-2
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MAINTENANCE MANUAL
TCAS-201-2
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 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 the Chassis Assy from the Case Assy 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 ON/OFF (Push-Push): AC line power to the device is connected ON or
disconnected OFF.
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.
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MAINTENANCE MANUAL
TCAS-201-2
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 TCAS-201-2 USES A SEALED-LEAD-BATTERY PACK. THE FOLLOWING WARNINGS
CONCERNING LEAD-ACID BATTERIES MUST BE HEEDED:
ODO NOT RECHARGE OUTSIDE THE TCAS-201-2.
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.
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MAINTENANCE MANUAL
TCAS-201-2
LIST OF EFFECTIVE PAGES
Page 1
Sep 1/04
LIST OF EFFECTIVE PAGES
CHAPTER/SECTION/SUBJECT PAGE DATE
Title/Copyright Page Sep 1/04
For Qualified Service Personnel Only Page Sep 1/04
Statements Sep 1/04
Warning/Caution Pages Sep 1/04
List of Effective Pages 1 through 2 Sep 1/04
Table of Contents 1 through 2 Sep 1/04
Introduction 1 through 2 Sep 1/04
2-Table of Contents 1 through 2 Sep 1/04
2-List of Illustrations 1 through 2 Sep 1/04
2-List of Tables 1 through 2 Sep 1/04
2-1-1 1 through 2 Sep 1/04
2-2-1 1 through 56 Sep 1/04
2-2-2 1 through 48 Sep 1/04
2-2-3 1 through 70 Sep 1/04
2-3-1 1 through 30 Sep 1/04
2-3-2 1 through 10 Sep 1/04
2-4-1 1 through 88 Sep 1/04
Appendix A 1 through 2 Sep 1/04
Appendix B 1 through 2 Sep 1/04
Appendix C 1 through 4 Sep 1/04
Appendix D 1 through 8 Sep 1/04
Appendix E 1 through 2 Sep 1/04
Appendix F 1 through 4 Sep 1/04
Appendix G 1 through 6 Sep 1/04
Appendix H 1 through 4 Sep 1/04
Index 1 through 4 Sep 1/04
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TCAS-201-2
LIST OF EFFECTIVE PAGES
Page 2
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MAINTENANCE MANUAL
TCAS-201-2
TABLE OF CONTENTS
Page 1
Sep 1/04
TABLE OF CONTENTS
Title Chapter/Section
Title/Copyright Page
For Qualified Personnel Only Page
Statements
Warning/Cautions Pages
Caution Page
List of Effective 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 - 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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TCAS-201-2
TABLE OF CONTENTS
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MAINTENANCE MANUAL
TCAS-201-2
INTRODUCTION
Page 1
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INTRODUCTION - TCAS-201-2 RAMP TEST SET
This manual contains the information necessary to test and repair the TCAS-201-2 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 - PARTS LIST
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MAINTENANCE MANUAL
TCAS-201-2
INTRODUCTION
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MAINTENANCE MANUAL
TCAS-201-2
2-TABLE OF CONTENTS
Page 1
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CHAPTER TWO
TCAS-201-2 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 2
(1) Scenario Test 2-2-1 2
(2) Reply Test 2-2-1 2
(3) Monitor Test 2-2-1 2
(4) Power & Frequency 2-2-1 2
(5) Self Test 2-2-1 4
D. Module Theory of Operation 2-2-1 7
(1) Power Supply 2-2-1 7
(2) Digital IF PCB Assy 2-2-1 11
(3) Front Panel Pulse PCB Assy 2-2-1 19
(4) RF Assy 2-2-1 37
(5) Front Panel Assy 2-2-1 54
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 2
(1) Safety 2-2-2 2
(2) ESD 2-2-2 3
(3) EMC and Safety Compliance 2-2-2 3
C. Requirements 2-2-2 3
(1) Performance 2-2-2 3
(2) Test Equipment 2-2-2 3
(3) Disassembly 2-2-2 3
(4) Environment 2-2-2 3
D. Verification Procedures 2-2-2 6
(1) Signal Generator 2-2-2 6
(2) Pulse Characteristics 2-2-2 8
(3) Parameters 2-2-2 11
(4) UUT Measurements 2-2-2 17
(5) Self Test 2-2-2 23
E. Verification Data Sheet 2-2-2 24
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MAINTENANCE MANUAL
TCAS-201-2
2-TABLE OF CONTENTS
Page 2
Sep 1/04
Title Chapter/Section/Subject
SECTION 2 - TROUBLESHOOTING (cont) 2-2
F. Calibration Procedures 2-2-2 31
(1) Power Supply 2-2-2 31
(2) RF Assy 2-2-2 32
(3) System 2-2-2 42
G. Calibration Data Sheet 2-2-2 46
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
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) Storage Compartment and Chassis Assy 2-3-1 3
(2) Battery 2-3-1 6
(3) Line Supply Assy 2-3-1 6
(4) Power Supply Assy 2-3-1 8
(5) Digital IF PCB Assy 2-3-1 10
(6) Front Panel Pulse PCB Assy 2-3-1 10
(7) RF Assy 2-3-1 12
(8) Front Panel Assy 2-3-1 21
(9) Flat Antenna Assy 2-3-1 28
(10) Motherboard PCB Assy 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 3
(1) Storage Compartment and Chassis Assy 2-3-2 3
(2) Battery 2-3-2 3
(3) Line Supply Assy 2-3-2 3
(4) Power Supply Assy 2-3-2 3
(5) Digital IF PCB Assy 2-3-2 3
(6) Front Panel Pulse PCB Assy 2-3-2 3
(7) RF Assy 2-3-2 4
(8) Front Panel Assy 2-3-2 5
(9) Flat Antenna Assy 2-3-2 5
(10) Motherboard PCB Assy 2-3-2 5
SECTION 4 - PARTS LIST 2-4
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MAINTENANCE MANUAL
TCAS-201-2
2-LIST OF ILLUSTRATIONS
Page 1
Sep 1/04
LIST OF ILLUSTRATIONS
Title Chapter/Section/Subject Page
System Block Diagram 2-2-1 3
Power Supply Assy Block Diagram 2-2-1 9
Digital IF PCB Assy Block Diagram 2-2-1 10
Clock Format Timing Diagram 2-2-1 12
Front Panel Pulse PCB Assy Block Diagram 2-2-1 18
Pulse Generator Data Transfer Timing Diagram 2-2-1 22
500 kHz Clock Timing Diagram 2-2-1 29
RF Assy Block Diagram 2-2-1 37
Attenuator PCB Assy Block Diagram 2-2-1 38
LO Source Assy and Source Module VCO PCB Ass Block Diagram 2-2-1 39
Mixer PCB Assy Block Diagram 2-2-1 41
Driver PCB Assy Block Diagram 2-2-1 43
Detector Assy Block Diagram 2-2-1 45
Trailing Edge Comparator Input Signals 2-2-1 46
Leading Edge Comparator Input Signals 2-2-1 47
Detector Comparator Pulses 2-2-1 47
Analog IF Assy Block Diagram 2-2-1 50
Decoder Assy Block Diagram 2-2-1 52
Level and Attenuation Test Setup Diagram 2-2-2 6
Pulse Characteristics Test Setup Diagram 2-2-2 8
Percent Reply Test Setup Diagram 2-2-2 11
Range Delay Test Setup Diagram 2-2-2 13
Frequency Measurement Test Setup Diagram 2-2-2 17
UUT Pulse Spacing Test Setup Diagram 2-2-2 20
Test Points and Adjustments 2-2-2 30
LO Source Test Setup Diagram 2-2-2 32
LO Detect Waveform 2-2-2 32
Attenuator VSWR Test Setup Diagram 2-2-2 34
Attenuator Test Setup Diagram 2-2-2 34
Receive Image Test Setup Diagram 2-2-2 36
Detector Pulse Width Test Setup Diagram 2-2-2 38
Direct Connect Set Test Setup Diagram 2-2-2 39
Threshold Test Setup Diagram 2-2-2 44
Composite Assy 2-2-3 3
Chassis Assy 2-2-3 4
Power Supply Assy 2-2-3 9
Line Supply Assy 2-2-3 15
Motherboard PCB Assy 2-2-3 17
Digital IF PCB Assy 2-2-3 19
Flat Antenna Assy 2-2-3 23
Front Panel Pulse PCB Assy 2-2-3 25
RF Assy 2-2-3 36
Front Panel Assy 2-2-3 59
Storage Compartment and Chassis Assy 2-3-1 4
TCAS-201-2 Rear View 2-3-1 5
Line Supply Assy 2-3-1 7
Power Supply Assy 2-3-1 9
RF Assy 2-3-1 11
Decoder Assy 2-3-1 13
Detector Assy 2-3-1 14
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MAINTENANCE MANUAL
TCAS-201-2
2-LIST OF ILLUSTRATIONS
Page 2
Sep 1/04
Title Chapter/Section/Subject Page
Analog IF Assy 2-3-1 17
SSB Assy 2-3-1 18
TCAS-201-2 Top View 2-3-1 21
Front Panel Assy 2-3-1 23
Power Termination Assy 2-3-1 26
Flat Antenna Assy 2-3-1 29
Mixer PC Board Assy 2-3-2 6
Solder Points for W1 (Backlight Wire Harness) 2-3-2 7
Flat Antenna Assy 2-3-2 9
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MAINTENANCE MANUAL
TCAS-201-2
2-LIST OF TABLES
Page 1
Sep 1/04
LIST OF TABLES
Title Chapter/Section/Subject Page
Self Test 2-2-1 5
Digitizer PAL Inputs and Outputs 2-2-1 15
Microprocessor U27001 Chip Selects 2-2-1 20
Pulse Generator Serialized Data Output 2-2-1 22
Interrogation Decoder Address Descriptions 2-2-1 25
Interrogation Decoder Control Register Bit Definition 2-2-1 26
Interrogation Decoder Status Register Bit Definition for Mode S 2-2-1 28
Interrogation Decoder Status Register Return Code for ATCRBS 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
Assembly Replacement Calibration Requirements 2-2-2 3
Verification Failure Calibration Requirements 2-2-2 4
Oscillator Compensation 2-2-2 40
Disassembly Tools 2-3-1 1
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MAINTENANCE MANUAL
TCAS-201-2
2-LIST OF TABLES
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