Racal Instruments AN/TRC-199 Manual

TO 31R2-2TRC199-1
OPERATION AND MAINTENANCE INSTRUCTIONS
WITH ILLUSTRATED PARTS BREAKDOWN
ORGANIZATIONAL LEVEL
RADIO SET
AN/TRC-199
(TACTICAL REPEATER)
RACAL COMMUNICATIONS, INC.
5 RESEARCH PLACE
ROCKVILLE, MD 20850
CONTRACT NO: F19628-91-D-0012
DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government agencies only for administrative or
operational use 15 June, 1993. Other requests for this document shall be referred to Sacramento ALC/TILBE, 3200
Peacekeeper Way, Suite 1, McClellan AFB, CA 95652-1026.
WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title
22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq).
Violations of these export laws are subject to severe criminal penalties.
HANDLING AND DESTRUCTION NOTICE - Handle in compliance with distribution statement and destroy by any
method that will prevent disclosure of contents or reconstruction of the document.
PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE
15 JUNE 1993
CHANGE 1 - 10 AUGUST 1994

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TABLE OF CONTENTS
Chapter Page
LIST OF ILLUSTRATIONS .........................................................................................................................iv
LIST OF TABLES .........................................................................................................................................iv
SAFETY SUMMARY ....................................................................................................................................v
FOREWORD .................................................................................................................................................ix
CHAPTER 1.0 GENERAL INFORMATION....................................................................................................... 1-3
1-1 DESCRIPTION AND PURPOSE. ....................................................................................................1-3
1-1.1 Equipment Function and Purpose. ...................................................................................1-3
1-1.2 Equipment Description. ...................................................................................................1-3
1-2 LEADING PARTICULARS. ............................................................................................................1-5
1-3 CAPABILITIES AND LIMITATIONS. ...........................................................................................1-6
1-4 EQUIPMENT SUPPLIED. ...............................................................................................................1-7
1-4.1 EQUIPMENT REQUIRED BUT NOT SUPPLIED. ......................................................1-8
1-5 SPECIAL TOOLS AND TEST EQUIPMENT. ................................................................................1-8
1-6 RELATED TECHNICAL MANUALS. ............................................................................................1-8
CHAPTER 2.0 INSTALLATION .......................................................................................................................... 2-1
2-1 INTRODUCTION. ............................................................................................................................2-1
Section I. INSTALLATION LOGISTICS ..................................................................................................2-1
2-2 SITE PREPARATION. .....................................................................................................................2-1
2-3 UNPACKING AND INSPECTIONS................................................................................................2-1
2-4 HOUSING. ........................................................................................................................................2-3
2-5 RECEIVING DATA..........................................................................................................................2-3
2-6 MATERIAL HANDLING.................................................................................................................2-3
2-7 CABLES............................................................................................................................................2-4
2-8 BUILDING AND OTHER SUPPORTING STRUCTURES. ...........................................................2-4
Section II. INSTALLATION PROCEDURES............................................................................................2-5
2-9 SPECIAL TOOLS AND EQUIPMENT REQUIRED FOR FIELD INSTALLATION. ...................2-5
2-10 INSTALLATION SEQUENCE.........................................................................................................2-5
2-10.1 Antenna/Mast Installation. ...............................................................................................2-5
2-10.2 Lithium Battery Installation. ............................................................................................2-9
2-10.3 Ground Rod Installation...................................................................................................2-9
2-10.4 External Power Supply. ...................................................................................................2-9
2-10.5 Diplexer Installation. .......................................................................................................2-9
2-10.6 Receiver-Transmitter Transceiver Module Installation....................................................2-9
CHAPTER 3.0 PREPARATION FOR USE AND RESHIPMENT .................................................................. 3-10
3-1 INTRODUCTION. ..........................................................................................................................3-10
Section I. PREPARATION FOR USE ......................................................................................................3-10
3-2 INSPECTION..................................................................................................................................3-10
3-3 POST-INSTALLATION CHECKOUT...........................................................................................3-10
3-3.1 Preliminary.....................................................................................................................3-10
3-3.2 Alignment and Adjustment. .............................................................................................3-2
3-3.3 Post-Installation Checkout Procedures. ...........................................................................3-2
Section II. PREPARATION FOR RESHIPMENT .....................................................................................3-2
3-4 PREPARING UNIT FOR RESHIPMENT........................................................................................3-2
3-5 PACKING. ........................................................................................................................................3-2
3-6 HANDLING AND STORAGE. ........................................................................................................3-2
3-6.1 Protective Measures for Electrical Connectors................................................................3-3
3-6.2 Preparation for Shipment and Storage. ............................................................................3-3
3-6.3 Handling. .........................................................................................................................3-3

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CHAPTER 4.0 OPERATION ................................................................................................................................. 4-1
4-1 INTRODUCTION. ........................................................................................................................... 4-1
4-2 CONTROLS AND INDICATORS. .................................................................................................. 4-1
4-2.1 Indicators, Controls and Switches. .................................................................................. 4-1
4-2.2 Power Supply Switches and Connectors. ........................................................................ 4-1
4-2.3 Connectors....................................................................................................................... 4-1
4-2.4 Diplexer Controls. ........................................................................................................... 4-1
Section II. OPERATING INSTRUCTIONS .............................................................................................. 4-7
4-3 INITIAL POWER-UP AND DIPLEXER TUNING PROCEDURES.............................................. 4-7
4-4 RECEIVING AND RETRANSMITTING MESSAGE. ................................................................... 4-8
4-5 COVERT OPERATIONS................................................................................................................. 4-8
4-6 RECEIVER-TRANSMITTERS........................................................................................................ 4-8
4-7 EQUIPMENT SHUTDOWN............................................................................................................ 4-8
Section III. EMERGENCY OPERATION ................................................................................................. 4-8
4-8 EMERGENCY POWER................................................................................................................... 4-8
4-9 ELECTROMAGNETIC PULSE PROTECTION............................................................................. 4-9
4-9.1 EMP Susceptibility.......................................................................................................... 4-9
4-9.2 EMP Protective Measures............................................................................................... 4-9
4-10 NUCLEAR, BIOLOGICAL, AND CHEMICAL(NBC) CONTAMINATION ................................ 4-9
CHAPTER 5.0 THEORY OF OPERATION ........................................................................................................ 5-1
Section I. FUNCTIONAL SYSTEM(S) OPERATION.............................................................................. 5-1
5-1 GENERAL. ....................................................................................................................................... 5-1
5-2 FUNCTIONAL SYSTEM(S) OPERATION. ................................................................................... 5-1
5-2.1 +15V DC-DC Converter Circuit Card Assembly (CCA) (A1). ....................................... 5-1
5-2.2 Repeater Control Circuit Card Assembly (CCA) (A3).................................................... 5-1
5-2.3 Parent Board Circuit Card Assembly (CCA) (A4). ......................................................... 5-1
5-2.4 Control Panel (A5). ......................................................................................................... 5-1
5-2.5 RF Power Amplifier Assembly (A6). .............................................................................. 5-1
5-2.6 +28V DC-DC Converter Circuit Card Assembly (CCA) (A7). ....................................... 5-3
5-2.7 Receiver-Transmitter....................................................................................................... 5-3
5-2.8 Antenna System............................................................................................................... 5-3
5-2.9 Diplexer........................................................................................................................... 5-3
5-2.10 AC/DC Power Supply (A2)............................................................................................. 5-3
Section II. FUNCTIONAL OPERATION OF ELECTRONIC CIRCUITS ............................................... 5-4
5-3 REPEATER CONTROL CIRCUIT CARD ASSEMBLY (CCA) (A3)............................................ 5-4
5-4 15 WATT POWER AMPLIFIER ASSEMBLY (A6)....................................................................... 5-4
Section III. FUNCTIONAL OPERATION OF MECHANICAL ASSEMBLIES ...................................... 5-4
CHAPTER 6.0 MAINTENANCE........................................................................................................................... 6-1
6-1 GENERAL. ....................................................................................................................................... 6-1
6-2 OPERATIONAL CHECKOUT. ....................................................................................................... 6-1
6-2.1 Power-up Verification. .................................................................................................... 6-1
6-2.2 Display Off Control......................................................................................................... 6-1
6-2.3 Receive Tune Mode Verification. ................................................................................... 6-2
6-2.4 Transmit Tune Mode Verification................................................................................... 6-2
6-2.5 Fault LED........................................................................................................................ 6-3
6-3 SERVICING. .................................................................................................................................... 6-3
6-3.1 Servicing Intervals........................................................................................................... 6-3
6-3.2 Inspection. ....................................................................................................................... 6-3
6-3.3 Preventive Maintenance. ................................................................................................. 6-3
6-4 TROUBLESHOOTING.................................................................................................................... 6-4
6-5 REMOVAL/REPLACEMENT PROCEDURES. ........................................................................... 6-10
6-5.1 Removal/Replacement Procedures - Operator............................................................... 6-10
6-5.2 Removal/Replacement Procedures - Repair Specialist.................................................. 6-12

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CHAPTER 7.0 ILLUSTRATED PARTS BREAKDOWN................................................................................... 7-1
Section I. INTRODUCTION ......................................................................................................................7-1
7-1 GENERAL.........................................................................................................................................7-1
7-2 MAINTENANCE PARTS LIST. ......................................................................................................7-1
7-3 NUMERICAL INDEX. .....................................................................................................................7-2
7-4 REFERENCE DESIGNATION INDEX. ..........................................................................................7-3
7-5 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES..................................................7-3
7-6 CAGE CODE SUMMARY. ..............................................................................................................7-4
Section II. MAINTENANCE PARTS LISTS ...........................................................................................7-10
Section III. NUMERICAL INDEX ...........................................................................................................7-21
Section IV. REFERENCE DESIGNATION INDEX................................................................................7-23
Section V. COMMON BULK ITEMS LIST.............................................................................................7-24
CHAPTER 8.0.......................................................................................................................................................... 8-1
8-1 SCOPE...............................................................................................................................................8-1
GLOSSARY
ALPHABETICAL INDEX

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LIST OF ILLUSTRATIONS
Figure 1-1. Radio Set AN/TRC-199......................................................................................................................... 1-0
Figure 1-2. Receiver-Transmitter RT-1695/TRC-199.............................................................................................. 1-4
Figure 1-3. Diplexer Front Panel (30-88 MHz)........................................................................................................ 1-4
Figure 2-1. Packaging Diagram for the Tactical Repeater ....................................................................................... 2-2
Figure 2-2. Antenna Mast/Antenna Installation (Sheet 1 of 6) ................................................................................ 2-5
Figure 2-3. Antenna Mast/Antenna Installation (Sheet 2 of 6) ................................................................................ 2-6
Figure 2-4. Antenna Mast/Antenna Installation (Sheet 3 of 6) ................................................................................ 2-6
Figure 2-5. Antenna Mast/Antenna Installation (Sheet 4 of 6) ................................................................................ 2-7
Figure 2-6. Antenna Mast/Antenna Installation (Sheet 5 of 6) ................................................................................ 2-7
Figure 2-7. Antenna Mast/Antenna Installation (Sheet 6 of 6) ................................................................................ 2-8
Figure 4-1. Location of Tactical Repeater Indicators, Controls and Switches ......................................................... 4-1
Figure 4-2. Location of Power Supply Switches (Power Supply Top View) ........................................................... 4-3
Figure 4-3. Location of Power Supply Connectors (Power Supply Side View) ...................................................... 4-4
Figure 4-4. Location of Tactical Repeater Unit Connectors..................................................................................... 4-5
Figure 4-5. Location of Tactical Repeater Diplexer Controls .................................................................................. 4-6
Figure 5-1. Tactical Repeater System, Functional Block Diagram .......................................................................... 5-2
Figure 5-2. Repeater Control CCA (A3), Functional Block Diagram ...................................................................... 5-5
Figure 5-3. 15 Watt Power Amplifier Assembly (A6), Functional Block Diagram ................................................. 5-6
Figure 7-1. Radio Set AN/TRC-199 (Sheet 1 of 2)................................................................................................... 7-8
Figure 7-2. Tactical Repeater Assembly (SS-4100806-501)................................................................................. 7-13
Figure 7-3. Power Amp Assembly, 15W (SS-4100853-501)................................................................................... 7-19
FO-1 Radio Set AN/TRC-199, Interconnection Diagram ............................................................................. FP-1
LIST OF TABLES
Table 1-1. Tactical Repeater Configurations (by Frequency Band)........................................................................ 1-3
Table 1-2. Leading Particulars ................................................................................................................................1-5
Table 1-3. Capabilities and Limitations .................................................................................................................. 1-6
Table 1-4. Equipment Supplied............................................................................................................................... 1-7
Table 1-5. Equipment Required But Not Supplied ................................................................................................. 1-8
Table 1-6. Related Technical Manuals.................................................................................................................... 1-8
Table 2-1. Tactical Repeater Packaging.................................................................................................................. 2-3
Table 2-2. Tactical Repeater Interconnecting Cables.............................................................................................. 2-4
Table 2-3. External Power Supply Switch Settings................................................................................................. 2-9
Table 4-1. Description of Indicators, Controls and Switches.................................................................................. 4-2
Table 4-2. Description of Power Supply Switches.................................................................................................. 4-3
Table 4-3. Description of Power Supply Connectors.............................................................................................. 4-4
Table 4-4. Description of Repeater Unit Connectors .............................................................................................. 4-5
Table 4-5. Description of Diplexer Controls........................................................................................................... 4-6
Table 5-1. Antenna System Frequency Band Vs Gain ............................................................................................ 5-3
Table 6-1. Initial Switch and Control Settings for Power-Up Verification ............................................................. 6-1
Table 6-2. Initial Switch and Control Settings for Receive Tune Mode Verification ............................................. 6-2
Table 6-3. Initial Switch and Control Settings for Transmit Tune Mode Verification............................................ 6-2
Table 6-4. Recommended Service Intervals............................................................................................................ 6-3
Table 6-5. Organizational Maintenance Guide - Operator...................................................................................... 6-5
Table 6-6. Organizational Maintenance Guide - Repair Specialist ......................................................................... 6-9
Table 6-7. Cross-Reference to Removal/Replacement Procedures ....................................................................... 6-10
Table 7-1. Radio Set AN/TRC-199....................................................................................................................... 7-10
Table 7-2. Tactical Repeater Assembly (SS-4100806-501).................................................................................. 7-15
Table 7-3. Power AMP Assembly, 15W (SS-4100853-501) ................................................................................ 7-20

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SAFETY SUMMARY
The following are general safety precautions that are not related to any specific procedure, and do not appear elsewhere
in this manual. These Safety Summaries are recommended precautions that all personnel must understand and apply
during any given phase of operation and maintenance. Each chapter has other specific warnings and cautions.
KEEP AWAY FROM LIVE CIRCUITS
Personnel must at all times observe all safety regulations. Do not replace components or make
adjustments inside equipment with power turned on. Under certain conditions, dangerous
voltages may exist when the power switch is in the off position due to charges retained by
capacitors. To avoid injury, always remove power and discharge and ground a circuit before
touching it.
RESUSCITATION
Personnel working with or near high voltages should be familiar with modern methods of
resuscitation. Such information may be obtained from the Director of Base Medical Services.
Lithium oxide batteries or cells may be used in the receiver-transmitter used in this equipment. They are potentially
hazardous if misused or tampered with before, during or after discharge. The following precautions must be strictly
observed to prevent possible injury to personnel or equipment damage.
Do not heat, incinerate, crush, puncture, disassemble, or otherwise mutilate the batteries.
Do not short circuit, recharge, or bypass internal fuse.
Do not store batteries in equipment during long periods of non-use (in excess of 30 days).
Turn off the equipment immediately if you detect battery compartment becoming unduly hot, hear battery cells
venting (hissing sounds), or smell irritating sulfur dioxide gas.
WARNING
WARNING
LITHIUM BATTERIES

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VOLTAGES WITHIN THIS EQUIPMENT ARE HIGH ENOUGH TO ENDANGER LIFE.
Covers are not to be removed except by persons qualified and authorized to do so and these
persons should always take extreme care once the covers have been removed.
Page
2-1 WARNING - Installation of the tactical repeater requires a minimum of two people.
2-1 WARNING - Removing the tactical repeater assembly from the shipping carton requires a minimum of two
persons.
2-5 WARNING - Ensure proper use of safety tools (work gloves and hard hat) during assembly and disassembly of
antenna.
2-6 WARNING - Before using the hammer, ensure a wedge is placed in the top of the hammer so that the hammer
head does not come loose, thereby endangering personnel.
3-3 WARNING - Before performing removal/replacement procedures, make sure power is removed from unit.
Failure to do so could result in personal injury or equipment damage.
6-10 WARNING - Before performing removal/replacement procedures, make sure power is removed from the unit
by disconnecting from power source. Failure to do so could result in personal injury and equipment damage.
6-11 WARNING - This equipment is capable of generating RF power sufficient to cause RF burns. During transmit,
care should be taken to eliminate the possibility of touching exposed RF output points such as the center
conductors of coaxial cables or antenna feedpoints.
6-12 WARNING - Before performing removal/replacement procedures, make sure power is removed from the unit.
Failure to do so could result in personal injury or equipment damage.
2-1 CAUTION - Exercise care when removing units from packing material in order to prevent damage to the unit.
3-3 CAUTION - Never apply pressure sensitive tape directly to connectors. This could damage connector pins.
3-3 CAUTION - Package all electrostatic discharge (ESD) sensitive assemblies in ESD bags before shipping or
storing.
3-3 CAUTION - Rough handling may cause unnecessary damage to electronic assemblies.
3-3 CAUTION - Electronic assemblies containing solid-state devices are susceptible to damage from static electrical
discharges. Wear protective clothing and grounded wrist straps.
3-3 CAUTION - Forcing any tilted or cocked electronic assembly into position may result in bent or broken pins.
3-4 CAUTION - When repairing an electronic assembly, be careful that the tool employed does not inadvertently
press against leads, pins, or other parts that are easily bent.
WARNING