Honeywell bendis king KLN 94 User manual

MAINTENANCE MANUAL
KLN 94
GPS NAVIGATION
SYSTEM
MANUAL NUMBER 006-15599-0000
REVISION 0 SEPTEMBER, 2000

MAINTENANCE MANUAL
KLN 94
GPS NAVIGATION
SYSTEM

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006-03140-0005 (4) inch Post Binder.
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COPYRIGHT NOTICE
©2000 Honeywell International Inc.
Reproduction of this publication or any portion thereof by any means without the express written
permission of Honeywell is prohibited. For further information contact the manager, Technical
Publications, Honeywell, One Technology Center, 23500 West 105th Street Olathe KS 66061
telephone: [phone].

WARNING
Prior to the export of this document, review for export license requirement is needed.
COPYRIGHT NOTICE
©2000 Honeywell International Inc.
Reproduction of this publication or any portion thereof by any means without the express written
permission of Honeywell is prohibited. For further information contact the manager, Technical
Publications, Honeywell, One Technology Center, 23500 West 105th Street Olathe KS 66061
telephone: [phone].

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JA TOC-1
SECTION IV
THEORY OF OPERATION
PARAGRAPH PAG E
4.1 GENERAL INFORMATION 4-1
4.1.1 GENERAL DESCRIPTION 4-1
4.1.2 BASIC CONSTRUCTION 4-1
4.2 BLOCK DIAGRAM THEORY 4-2
4.2.1 POWER BOARD 4-2
4.2.2 FRONT PANEL ASSEMBLY 4-2
4.2.3 GPS XPRESS RECEIVER 4-2
4.2.4 MAIN BOARD 4-2
4.2.5 UNIT INTERCONNECTION 4-2
4.3 DETAILED CIRCUIT THEORY 4-21
4.3.1 POWER BOARD 4-21
4.3.2 FRONT PANEL MODULE ASSEMBLY 4-26
4.3.3 GPS XPRESS RECEIVER 4-27
4.3.4 MAIN BOARD 4-27
SECTION V
MAINTENANCE
PARAGRAPH PAG E
5.1 INTRODUCTION 5-1
5.2 TEST AND ALIGNMENT 5-1
5.2.1 TEST EQUIPMENT REQUIRED 5-1
5.2.2 STANDARD GPS TEST SIGNAL DESCRIPTION 5-1
5.2.3 ALIGNMENT PROCEDURE 5-1
5.2.4 FINAL TEST PROCEDURE 5-8
5.3 OVERHAUL 5-21
5.3.1 VISUAL INSPECTION 5-21
5.3.2 CLEANING 5-22
5.3.3 REPAIR 5-27
5.3.4 DISASSEMBLY 5-31
5.3.5 ASSEMBLY 5-35
5.4 TROUBLESHOOTING 5-35

BENDIX/KING KLN 94
TOC-2 15599M00.JA Rev 0, Sept/2000
SECTION VI
ILLUSTRATED PARTS LIST
PARAGRAPH PAG E
6.1 General 6-1
6.2 Revision Service 6-1
6.3 List of Abbreviations 6-1
6.4 Sample Parts List 6-3
6.5 KLN 94 FINAL ASSEMBLY AND SYSTEM SOFTWARE 6-5
6.6 KLN 94 FRONT PANEL ASSY. 6-15
6.7 KLN 94 BUTTON/BACKLIGHT ASSY. 6-21
6.8 KLN 94 BUTTON BOARD 6-25
6.9 KLN 94 SWITCH BOARD ASSY. 6-31
6.10 KLN 94 SWITCH BOARD 6-35
6.11 KLN 94 GPS XPRESS PROGRAMMED BOARD 6-45
6.12 KLN 94 PROGRAMMED MAIN BOARD 6-57
6.13 KLN 94 SUPPRESSOR BOARD 6-105
6.14 KLN 94 BUS I/O BOARD 6-111
6.15 KLN 94 POWER BOARD 6-117
LIST OF ILLUSTRATIONS
FIGURE PAG E
4-1 KLN 94 UNIT BLOCK DIAGRAM 4-3
4-2 KLN 94 POWER SUPPLY BLOCK DIAGRAM 4-5
4-3 KLN 94 FRONT PANEL BLOCK DIAGRAM 4-9
4-4 KLN 94 HOST MICROPROCESSOR BLOCK DIAGRAM 4-11
4-5 KLN 94 GRAPHICS MICROPROCESSOR BLOCK DIAGRAM 4-13
4-6 KLN 94 I/O BLOCK DIAGRAM 4-15
4-7 KLN 94 UNIT INTERCONNECTION DIAGRAM 4-19
5-1 KLN 89/89B/94 TEST HARNESS 5-37
5-2 PC INTERFACE DRAWING/SOFTWARE UPDATE TOOL KIT 5-43
5-3 KTS 143 TEST FIXTURE 5-45
5-4 KI 229 RADIO MAGNETIC INDICATOR 5-47
5-5 KLN 94 MAIN BOARD TROUBLESHOOTING FLOWCHART 5-49

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JA TOC-3
LIST OF ILLUSTRATIONS (cont.)
FIGURE PAG E
5-6 KLN 94 POWER BOARD TROUBLESHOOTING FLOWCHART 5-53
6-1 SAMPLE PARTS LIST 6-3
6-2 KLN 94 ASSEMBLY DRAWING 6-7
6-3 KLN 94 FRONT PANEL ASSEMBLY DRAWING 6-17
6-4 KLN 94 FRONT PANEL BUTTONS/BACKLIGHT DRAWING 6-23
6-5 KLN 94 BUTTON BOARD DRAWING 6-27
6-6 KLN 94 BUTTON BOARD SCHEMATIC 6-29
6-7 KLN 94 FRONT MECHANICAL SWITCH ASSEMBLY DRAWING 6-33
6-8 KLN 94 SWITCH BOARD DRAWING 6-37
6-9 KLN 94 SWITCH BOARD SCHEMATIC 6-41
6-10 KLN 94 GPS XPRESS BOARD ASSEMBLY DRAWING 6-49
6-11 KLN 94 GPS XPRESS BOARD SCHEMATIC 6-51
6-12 KLN 94 MAIN BOARD ASSEMBLY DRAWING 6-69
6-13 KLN 94 MAIN BOARD SCHEMATIC 6-77
6-14 KLN 94 SUPPRESSOR BOARD ASSEMBLY DRAWING 6-107
6-15 KLN 94 SUPPRESSOR BOARD SCHEMATIC 6-109
6-16 KLN 94 BUS I/O BOARD ASSEMBLY DRAWING 6-113
6-17 KLN 94 BUS I/O BOARD SCHEMATIC 6-115
6-18 KLN 94 POWER BOARD ASSEMBLY DRAWING 6-123
6-19 KLN 94 POWER BOARD SCHEMATIC 6-127
LIST OF TABLES
TABLE PAG E
4-1 Assembly Designations 4-1
4-2 ADC Channels 4-28
4-3 System Interrupts 4-28
4-4 Host Processor Address Map 4-29
4-5 Graphics Microprocessor Address Map 4-30
4-6 Graphics Microprocessor Interrupts 4-31
4-7 Graphics Microprocessor Discrete I/O 4-31
4-8 Peripheral Chip Selects 4-38

BENDIX/KING KLN 94
TOC-4 15599M00.JA Rev 0, Sept/2000
LIST OF TABLES (cont.)
TABLE PAG E
5-1 Recommended Cleaning Agents 5-23
5-2 Unsafe Cleaning Agents 5-24

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JA Page 4-1
SECTION IV
THEORY OF OPERATION
4.1 GENERAL INFORMATION
4.1.1 GENERAL DESCRIPTION
The KLN 94 is a panel-mounted, long range, GPS based airborne navigation system with a data-
base. The KLN 94 provides VFR, IFR enroute, terminal and non-precision approach functions.
The KLN 94 is certified to TSO C129a.
The primary purpose of the KLN 94 is to provide the pilot with present position information and to
display guidance information with respect to a user defined flight plan. Flight plan information is
entered by the user via various knobs and buttons located on the front panel.
The KLN 94 can use its present position information to determine crosstrack error, distance-to-
waypoint, ground speed, track angle, time-to-waypoint, bearing-to-waypoint, and advisory VNAV
guidance. The KLN 94 also has instrument approach capabilities.
The KLN 94 can also output some of this information for use by other devices. The internal data-
base of the KLN94 contains information concerning airports, VORs, NDBs, intersections, SID/
STARs, and outer markers located throughout the world. Waypoints are stored in the database
by their ICAO identifiers. The ICAO identifiers are taken directly from Jeppesen-Sanderson or gov-
ernment aeronautical charts. This data allows the pilot to create flight plans with minimum effort.
The KLN 94 can also store non-precision approaches. This allows the pilot to select an approach
as a whole, rather than entering the approach waypoint by waypoint.
Information in the database is updated on a perpetual basis. The KLN 94 is designed so that the
user may easily remove the old database and install a current database. The database is housed
in a data card which plugs into the front of the KLN 94. The database can also be updated by load-
ing the information with a personal computer via RS-232 serial interface.
For more information on the availability and cost of updating the database of the KLN 94, refer to
the KLN 94 Pilot’s Guide, P/N 006-18207-0000.
A color liquid crystal display (LCD) is used to display the navigation information. Connections to
the unit are made through one 37 pin and one 25 pin D-sub connector and one BNC coaxial con-
nector all located at the rear of the unit. Also, a phone jack is located on the front panel.
4.1.2 BASIC CONSTRUCTION
The KLN 94 contains several circuit boards and assemblies which are listed in Table 4-1, along
with reference series and connector information.
TABLE 4-1 ASSEMBLY DESIGNATIONS
ASSEMBLY PART NUMBER REFERENCE
SERIES
CONNECTORS
GPS XPRESS BOARD 200-08825-0000 500 J501, J502
BUTTON BOARD 200-09641-0001 1000 J1007, J1017
BUS I/O BOARD 200-09642-0001 3000 J945, J3005
SUPPRESSOR BOARD 200-09665-0001 4000 J4005
MAIN BOARD 200-09638-0001 5000 J941, J942, J5001, J5003, J5004, J5005,
J5006, J5007, J5009, J5100, J5101, J5102
POWER BOARD 200-09639-0001 6000 J943, J6005, J6008
SWITCH BOARD 200-09640-0001 7000 J7001, J7005, J7008, J7011

BENDIX/KING KLN 94
Page 4-2 15599M00.JA Rev 0, Sept/2000
4.2 BLOCK DIAGRAM THEORY
Figure 4-1is a block diagram showing the basic signal flow through a KLN 94 GPS RNAV.
4.2.1 POWER BOARD
The Power Board block diagram isshown inFigure 4-2.
The power supply uses a flyback converter circuit to transform the aircraft power bus voltage
(11-33 volts) into the required voltages for the KLN 94’s internal circuitry. The power supply in-
corporates over voltage and short circuit protection to minimize the possibility of damage occurring
in the power supply or other circuitry.
4.2.2 FRONT PANEL ASSEMBLY
The Front Panel block diagram isdepicted by Figure 4-3.
The Front Panel Assembly acts as the unit’s pilot interface. It includes the liquid crystal display
(LCD) with backlighting, control switches, and pushbuttons. Specific boards included within are
the Button Board and the Switch Board.
4.2.3 GPS XPRESS RECEIVER
CAUTION
DO NOT ATTEMPT TO ALIGN OR REPAIR
THE GPS PXPRESS RECEIVER BOARD (P/N
200–08825–0000). THIS BOARD IS NOT A
FIELD SERVICEABLE ASSEMBLY
4.2.4 MAIN BOARD
The Main Board block diagram isdepicted by Figures 4-4, 4-5, and 4-6.
The Main Board includes both microprocessors and input/output circuitries. The Bus I/O Board
and Suppressor Boards interface directly with the Main Board.
4.2.5 UNIT INTERCONNECTION
The UnitInterconnection diagram is depicted by Figure 4-7.
This diagram shows the relationships between the various board connectors within the KLN 94.

BENDIX/KING KLN 94
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FIGURE 4-1
KLN 94 UNIT BLOCK DIAGRAM

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-5
FIGURE 4-2
KLN 94 POWER SUPPLY BLOCK DIAGRAM (Sheet 1 of 2)

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-7
FIGURE 4-2
KLN 94 POWER SUPPLY BLOCK DIAGRAM (Sheet 2 of 2)

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-9
FIGURE 4-3
KLN 94 FRONT PANEL BLOCK DIAGRAM

BENDIX/KING KLN 94
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FIGURE 4-4
KLN 94 HOST MICROPROCESSOR BLOCK DIAGRAM

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-13
FIGURE 4-5
KLN 94 GRAPHICS MICROPROCESSOR BLOCK DIAGRAM

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-15
FIGURE 4-6
KLN 94 I/O BLOCK DIAGRAM (Sheet 1 of 2)

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-17
FIGURE 4-6
KLN 94 I/O BLOCK DIAGRAM (Sheet 2 of 2)

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JWA Page 4-19
FIGURE 4-7
KLN 94 UNIT INTERCONNECTION DIAGRAM

BENDIX/KING KLN 94
Rev 0, Sept/2000 15599M00.JA Page 4-21
4.3 DETAILED CIRCUIT THEORY
4.3.1 POWER BOARD
4.3.1.1 General
Refer to Figure 4-2and Power Board section of the Illustrated Parts Listas an aid for the following
discussion. The KLN 94 power supply produces the +5.0V, +9V, -12V, +13V, -15V, and +20V
(V_LCD_DRIVE) DC voltages. The power supply configuration enables the KLN 94 to operate on
any input voltage from +9.0VDC (a minimum of +10.0VDC for start-up) to +33VDC with no modi-
fication or rewiring. Also, the unit power consumption is virtually independent of the input voltage.
Current flowing through the primary windings of the power transformer T6001 is alternately
switched, on then off, by Q6016. When the primary current is turned on, energy is stored in the
transformer’s magnetic field. When the primary current is turned off, the current flowing in the sec-
ondary windings dissipates the stored energy. Five taps on the secondary winding of T6001 are
then rectified and filtered to produce the voltages necessary for operation of the KLN 94. The KLN
94 Power Board provides the required DC supply voltages for all circuitry within the unit.
4.3.1.2 Power Supply Circuitry
4.3.1.2.1 Power Input
Power input to the KLN 94 (11-33_VDC_A_C_POWER) is supplied to pin 19 of J942 on the MAIN
Board. On the MAIN Board, the input power is RF bypassed by a 1000pF and a 1uF capacitor.
The unit is protected from overvoltage damage by an 85V transorb. The input power then passes
through a filter consisting of a 2.5 turn coil, a .01uF and a 1uF capacitor through a 15uH inductor,
and a .1uF capacitor. Then power is passed to the Power Board via pins 30, 31 and 32 of J5006.
On the Power Board, input power is supplied to the +33VDC Overvoltage Shutdown circuit.
4.3.1.2.2 Overvoltage Shutdown Circuit
This circuit senses the input voltage and turns on Q6014 if the input voltage rises above a nominal
voltage of +36VDC. At input voltages less than this, the voltage is low enough to keep zener diode
CR6014 out of conduction.
In the normal condition, no current flows through R6045 keeping the base-emitter junction of
Q6014 at 0V. This will keep Q6014 turned off allowing the gate-source voltage of Q6015 to be
negative (the gate-source voltage of Q6015 is clamped at a maximum of -9.1V by CR3015) and
Q6015 is turned on for normal operation.
If the input voltage increases to a level above the sum of the zener voltage of CR6014 and the
forward drop of CR6013, current flows through R6045. This establishes a negative base-emitter
voltage that turns on Q6014 which clamps the gate-source voltage of Q6015 at -0.2V turning it off.
When Q6015 is off, input power is disconnected. All of the components connected to the output
of this circuit are thus protected from any voltage exceeding +36VDC.
The Overvoltage Shutdown circuit output to the superflags and annunciators, (PROT_AC_PWR),
is routed back to the Main Board through a filter consisting of L6002, C6029, and C6056 while the
input power for all power supply circuitry is routed to the Input Hash Filter.
4.3.1.2.3 Input Hash Filter
The Input Hash Filter is a pi filter consisting of L6003, C6015, C6016, C6022, and C6026. The
filter reduces ripple on the input power line and protects the power supply circuitry from any exter-
nally induced ripple voltage. The hash filter output is routed to the input power steering diode
CR6016. CR6016 couples either the Input Hash Filter circuit output or the Backup Capacitor cir-
cuit output to the Low-Voltage (LV) Flyback Transformer (XFMR_HI) and to the front panel On/Off
switch (PWR_SW_HI).