Garmin GDL 90 UAT Quick start guide

GDL 90 UAT Data Link Sensor
Capstone Upgrade Instructions
April 2004
560-1057-00 Rev A

GDL 90 Capstone Upgrade Instructions
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GDL 90 Capstone Upgrade Instructions i
HISTORY OF REVISIONS
Revision Date Description
-- 3/17/04 Initial release
A 4/30/04 Remove “STC Pending” watermark. List CD in ordering info. Add
washer to install kit, update APM p/n (Table 1-2). Add tray side view
(Figure 2-2). APM wiring 4 inches maximum (2.5.1.2). Add
transmitter caution statement (2.5.1.3).
ORDERING INFORMATION
To receive additional copies of GDL 90 publications, order the following part numbers:
GDL 90 Installation Manual 560-1049-xx
GDL 90 Capstone Upgrade Instructions 560-1057-xx
GDL 90 Product CD 140-0063-xx

ii GDL 90 Capstone Upgrade Instructions
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Table of Contents
GDL 90 Capstone Upgrade Instructions 560-1057-00 iii
TABLE OF CONTENTS
1GENERAL INFORMATION ................................................................................................................................. 1-1
1.1 SCOPE........................................................................................................................................................... 1-1
1.2 PACKAGE CONTENTS .................................................................................................................................... 1-2
2INSTALLATION ................................................................................................................................................. 2-1
2.1 PRE-INSTALLATION INFORMATION................................................................................................................ 2-1
2.2 MATERIALS NOT SUPPLIED........................................................................................................................... 2-1
2.2.1 MATERIALS REQUIRED BUT NOT SUPPLIED ............................................................................................. 2-1
2.3 SPECIAL TOOLS REQUIRED ........................................................................................................................... 2-1
2.4 EQUIPMENT MOUNTING................................................................................................................................2-2
2.4.1 ADAPTER PLATE &MOUNTING TRAY INSTALLATION .............................................................................. 2-2
2.5 ELECTRICAL CONNECTIONS .......................................................................................................................... 2-4
2.5.1 CABLING AND WIRING ............................................................................................................................. 2-4
2.5.2 INTERFACE CONNECTOR DEFINITION ....................................................................................................... 2-8
LIST OF TABLES
TABLE 1-1 -PACKAGE CONTENTS ............................................................................................................. 1-2
TABLE 1-2 -INSTALLATION KIT CONTENTS (PN 424-6081-150)............................................................... 1-2
TABLE 2-1 -CRIMP TOOL FOR P/N 245-0027 ............................................................................................ 2-1
TABLE 2-2 -INTERFACE CONNECTORS ...................................................................................................... 2-4
TABLE 2-3 -CRIMP CONTACT SPECIFICATIONS ......................................................................................... 2-4
LIST OF ILLUSTRATIONS
FIGURE 2-1: GDL 90 ADAPTER PLATE...................................................................................................... 2-2
FIGURE 2-2: GDL 90 MOUNTING TRAY .................................................................................................... 2-3
FIGURE 2-3: APM AND MAINTENANCE CONNECTOR INSTALLATION ....................................................... 2-5
FIGURE 2-4: GPS ANTENNA CONNECTIONS.............................................................................................. 2-7
FIGURE 2-5: RIGHT-ANGLE COAX CONNECTOR ASSEMBLY..................................................................... 2-7
FIGURE 2-6: REAR CONNECTOR LAYOUT ................................................................................................. 2-8

Table of Contents
iv 560-1057-00 GDL 90 Capstone Upgrade Instructions
NOTES

General Information
GDL 90 Capstone Upgrade Instructions 560-1057-00 Rev A
1-1
1 GENERAL INFORMATION
1.1 SCOPE
This manual contains the instructions for upgrading existing Capstone UAT to the GDL 90 Data link
Sensor. It is intended for use by persons certified by the Federal Aviation Administration (FAA) to install
avionics devices.
This document is to be used as a supplement to the GDL 90 Installation Manual, Part No 560-1049-xx,
which is included in the GDL 90 Product CD. The information in this manual is STC approved. Only
the equipment interfaces covered in this manual are within the scope of this STC. Refer to the GDL 90
Installation Manual for more descriptions on interfaces.
NOTE
Since the upgrade installation is different from the standard installation in mounting tray
and hardware, this manual should be used to install the GDL 90 in existing Capstone
installations and the GDL 90 Installation Manual should be used for certification
limitation, product specifications, system checkout, troubleshooting and maintenance
procedures.

General Information
560-1057-00 Rev A GDL 90 Capstone Upgrade Instructions
1-2
1.2 PACKAGE CONTENTS
The GDL 90 Capstone Upgrade Installation Kit includes most necessary items for installation other than
supplies normally available at the installation shop, such as wire and cable ties, circuit breakers. The
items included in the package are listed in Table 1-1 and Table 1-2.
Table 1-1 - Package Contents
Part # Qty Description
424-6081-150 1 GDL 90 Capstone Upgrade Installation Kit (see Table 1-2 for
detail)
430-6081-1xx-xxx 1 GDL 90 UAT Data Link Sensor
140-0063-xx 1 GDL 90 Product CD
560-1057-xx 1 GDL 90 Capstone Upgrade Instructions
Table 1-2 - Installation Kit Contents (PN 424-6081-150)
Part # Qty Description
162-0043 3 Connector, coax, RA, PNL MNT
265-0007 3 Retainer Ring, ext,7/16 shaft
240-0008 3 Washer, 0.446 ID 0.56 OD
162-1574 1 Receptacle DSUB 9-pin
310-0467-00 1 Capstone Phase 1 Adapter Plate
500-0290-00 1 Capstone Phase 1 Adapter Cable
202-0002 8 Cable tie
245-0027 7 Crimp contact, DSUB, 20 to 24 AWG wire
224-0404 4 Screw, 4-40 x 1/4 SS flat head Phillips 82 deg.
310-0461-00 1 Cover Mounting Tray GDL 90
310-0462-00 1 Mounting Tray GDL 90
430-6200-000 1 Aircraft Personality Module (APM), GDL 90

Installation
GDL 90 Capstone Upgrade Instructions 560-1057-00 Rev A
2-1
2 INSTALLATION
This section describes the installation of the GDL 90 including mounting, wiring, and connections. Refer
to the GDL 90 Installation Manual for limitations and post-installation configuration and checkout
procedures.
2.1 PRE-INSTALLATION INFORMATION
Always follow acceptable avionics installation practices per FAA Advisory Circulars (AC) 43.13-1B,
43.13-2A, or later FAA approved revisions of these documents.
Follow the installation procedure in this section as it is presented for a successful installation. Read the
entire section before beginning the procedure. Prior to installation, consider the structural integrity of the
GDL 90 installation as defined in AC 43.13-2A, Chapter 1. Perform the post installation checkout before
closing the work area in case problems occur.
Complete an electrical load analysis in accordance with AC 43.13-1B, Chapter 11, on the aircraft prior to
starting modification to ensure aircraft has the ability to carry the GDL 90 load. Document the results of
the electrical load analysis on FAA Form 337.
2.2 MATERIALS NOT SUPPLIED
2.2.1 MATERIALS REQUIRED BUT NOT SUPPLIED
The GDL 90 is intended for use with standard aviation accessories. The following items are required for
the installation, but not supplied:
•Wire (MIL-W-22759/16 or equivalent)
•Shielded wire (MIL-C-27500 or equivalent)
•Circuit breakers
•Ring terminals (for grounding)
2.3 SPECIAL TOOLS REQUIRED
Some of the connectors use crimp contacts. The tables below identify crimp tools required to ensure
consistent, reliable crimp contact connections for the rear D-SUB connectors. The tables define one
source for the crimp tool. Alternate equivalent tools may be used.
Table 2-1 - Crimp Tool for P/N 245-0027
Description ITT/Cannon P/N Military number
Insertion/Extraction tool CIET-20HD 980-200-426 M81969/39-01
Crimp tool 995-0001-584 M22520/2-01
Positioner 995-0001-604 M22520/2-08
Below is the contact for ITT/Cannon crimp tools:
ITT Cannon Phone [phone]
1851 E. Deere Ave FAX [phone]
Santa Ana, CA 92705-6500

Installation
560-1057-00 Rev A GDL 90 Capstone Upgrade Instructions
2-2
2.4 EQUIPMENT MOUNTING
The Capstone Upgrade Installation Kit is intended for the replacement of the old UAT radio and tray
with the GDL 90 and tray in the same mounting holes.
2.4.1 ADAPTER PLATE &MOUNTING TRAY INSTALLATION
Remove the old UAT radio and tray. Install the adapter plate using four 8-32 pan-head screws
(MS35206, AN526 or equivalent) in the same mounting holes used for the old tray. Install the GDL 90
mounting tray on top of the adapter tray using four 8-32 pan-head screws. Refer to Figure 2-1 and Figure
2-2 for the GDL 90 adapter plate and mounting tray dimensions.
After the adapter cable is installed to the mounting tray back plate, route wiring bundle as appropriate.
Use cable ties to secure the cable assemblies and coax to the holes provided in the side of the connector
plate to provide strain relief for the cable assemblies. The cable shields should be grounded directly to a
lug mounted to one of the holes on the side of the connector plate, keeping the ground leads to a
maximum of 3 inches long.
Optional cover is provided for installations that need extra moisture protection. Install cover to aft side
of tray using 4 provided screws.
Figure 2-1: GDL 90 Adapter Plate

Installation
GDL 90 Capstone Upgrade Instructions 560-1057-00 Rev A 2-3
Figure 2-2: GDL 90 Mounting Tray

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560-1057-00 Rev A GDL 90 Capstone Upgrade Instructions
2-4
2.5 ELECTRICAL CONNECTIONS
The GDL 90 Capstone Upgrade Installation Kit includes the adapter cable and three coax connectors.
The connector layouts are shown in Figure 2-6. The D-sub connectors use the supplied crimp contacts as
specified in Table 2-2. Make the crimp connections with the crimp tool specified.
Table 2-2 - Interface Connectors
Figure 2-6 Connector Crimp Contact
Ref. Description P/N Description P/N Description
P1 Main System 162-1575 15 Pin D-Sub Receptacle 245-0027 20-24 AWG socket contact
P2 I/O 162-1577 37 Pin D-Sub Receptacle 245-0027 20-24 AWG socket contact
n/a Maint. Port 162-1574 9 Pin D-Sub Receptacle 245-0027 20-24 AWG socket contact
P3 GPS antenna 162-0043 Coax connector, right angle N/A N/A
P4 UAT ant (top) 162-0043 Coax connector, right angle N/A N/A
P5 UAT ant (bot) 162-0043 Coax connector, right angle N/A N/A
The following table shows the specifications for the crimp contacts. Alternate crimp contact part
numbers may be used that are equivalent to those specified in the table below.
Table 2-3 - Crimp Contact Specifications
Garmin AT Part Number 245-0027
Description 20-24 AWG crimp socket contact
Color bands Orange/Blue/Gray
ITT/Cannon P/N 031-1007-042
Military number M39029/63-368
2.5.1 CABLING AND WIRING
2.5.1.1 Adapter Cable
An adapter cable is provided with the GDL 90 Upgrade Installation Kit. Install the adapter cable as
follows:
•Mount the DB15 and DB37 connectors of the cable to the mounting tray backplate
•Connect the DB37 connector of the adapter cable to the DB37 connector of the existing wiring.
Fasten with 2 screws (provided.)
•Attach cable ground lug to one of the holes on the side rail of backplate with a #4 screw
2.5.1.2 APM and Maintenance Connector
Connect the micro APM to the DB15 connector of the adapter cable using crimp socket contacts
(provided). The APM may be fastened to the backplate of the tray close to the 37-pin connector using
cable ties through holes on the backplate. Refer to Figure 2-3 for more details. APM wiring must be 4
inches maximum length.
Connect the DB9 Maintenance PC connector to the DB15 connector of the adapter cable using crimp
socket contacts (provided) and 3-conductor wire. The Maintenance DB9 connector should be secured

Installation
GDL 90 Capstone Upgrade Instructions 560-1057-00 Rev A 2-5
from vibration and located in a convenient location for easy connection to a computer as the computer
will be used to configure and troubleshoot the GDL 90. The length for this cable should not exceed 20
feet.
Figure 2-3: APM and Maintenance Connector Installation
2.5.1.3 Antenna Connectors
UAT antenna cables from the previous UAT system need to be modified (or extended if not of sufficient
reach) to right-angle coax connectors (Part No. 162-0043). Refer to Figure 2-5 for assembly instructions.
CAUTION
Operating the GDL 90 with no RF terminations on the Top or Bottom UAT Antenna
ports can result in equipment damage. Always operate the GDL 90 with the Top and
Bottom UAT Antenna ports terminated with a VSWR ratio of 3.0:1 or less.
For the GPS connection, there are 3 wiring options as depicted in Figure 2-4. GPS signal connection to
the MX20 shall be disconnected and rerouted to the GDL 90. If only one GPS antenna is installed, a
signal splitter may be used to provide GPS signal to the GX60 and the GDL 90 as long as the primary
navigator, the GX60, provides power to the splitter and the total cable loss from the antenna to the GDL
90 is from 3 to 7 db. If SatCom is installed on the aircraft, the cable loss shall be 3 dB minimum to
ensure proper interference rejection from SatCom. The coaxial connectors and adapters, such as TNC to
BNC and signal splitter, add additional loss to the cable and should be considered when computing the
cable loss. A typical loss of 0.2 dB can be used for each connection. The typical cable loss for 20 feet of
RG-400 coax with a connector one each end is 4 dB.
During the post-installation checkout, susceptibility to harmonics of VHF comm. transmitters will be
evaluated. If problems arise, then better isolation, or distance, may be required between the GPS and

Installation
560-1057-00 Rev A GDL 90 Capstone Upgrade Instructions
2-6
comm antennas, or a 1575.42 MHz notch filter may be installed in series with the antenna coax of the
VHF comm transceiver to reduce or eliminate the harmonic interference. A notch filter (part #162-1059)
is available from Garmin AT.
If a VHF comm transmitter causes problems with the GPS on the selected frequencies as listed in the
post-installation checkout, the problem may be due to the ELT. This can be verified by disconnecting the
ELT antenna coax at the ELT unit. If the ELT is found to cause the problem, then contact the ELT
manufacturer or replace the ELT.
NOTE
To preserve certification integrity, it is important that the GX60 continues providing
power to the GPS antenna splitter, if one is used.

Installation
GDL 90 Capstone Upgrade Instructions 560-1057-00 Rev A 2-
7
Figure 2-4: GPS Antenna Connections
0.125
Insulation
1.000
STEP 1
Cable
Shrink
Tube
Matching Ring
Cap
STEP 3
STEP 4
-Slide shrink tube over cable.
-Strip cable as shown.
Solder Center
Conductor
-Solder cap into place, 2 Places.
-Shrink tube as shown.
Solder Cap
2 Places
STEP 2
.125
Shield 0.250
-Flare Outer Shield as Shown
Solder Outer Shield
to Connector -Place cable in connector as shown placing inner
shield inside connector.
-Flatten outer shield against connector.
-Solder outer shield to connector.
-Solder center conductor
-Slide matching ring into connector and around
conductor.
-Attach cap.
Figure 2-5: Right-Angle Coax Connector Assembly

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560-1057-00 Rev A GDL 90 Capstone Upgrade Instructions
2-8
2.5.2 INTERFACE CONNECTOR DEFINITION
Figure 2-6: Rear Connector Layout