SANDIA aerospace SAE5-35 User manual

SANDIA aerospace, Inc.SANDIA aerospace, Inc.
SANDIA aerospace, Inc.SANDIA aerospace, Inc.
SANDIA aerospace, Inc.
3700 Osuna Rd. NE, Suite 711
Albuquerque,NM87109 305186-00 Rev.3
SAE5-35
Altitude Data System
Installation Manual

This document and the information contained herein is the proprietary data of SANDIA aerospace,
Inc. No part of this document may be transmitted, reproduced, or copied in any form or by any
means without the prior written consent of SANDIA aerospace, Inc. Due to SANDIA aerospace’s
continued product and quality improvement programs, information contained in this document is
subject to change without prior notice.
Copyright 2000 SANDIA aerospace, Inc., All rights reserved. Printed in USA
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Record of Revisions
1

Table Of Contents
RecordofRevisions.............................................................................................................. 1
Table of Contents ................................................................................................................ 2
List of Illustrations .............................................................................................................. 2
Section 1 - General Description.......................................................................................... 3
1.1 Introduction............................................................................................................ 3
1.1.1 Product Description ....................................................................................... 3
1.2Technical Characteristics ........................................................................................ 3
1.2.1 PhysicalCharacteristics ................................................................................ 3
1.2.2 Operational Characteristics .......................................................................... 3
1.2.3 Gillham Grey Code Output........................................................................... 4
1.2.4 AIM Outputs ................................................................................................ 4
1.2.5 Discrete Inputs ............................................................................................. 4
1.2.6 RS-232 Outputs............................................................................................ 4
1.2.6.1 Standard Mode ..................................................................................... 4
1.2.6.2 Extended Mode..................................................................................... 5
1.2.7 Certification ................................................................................................... 5
EnvironmentalQualification Form...................................................................................... 6
Section 2 - Installation Considerations ............................................................................... 7
2.1 Introduction............................................................................................................ 7
2.2 Mounting Considerations ....................................................................................... 7
2.3 Cooling ................................................................................................................... 7
Section 3 - Installation Procedures ..................................................................................... 8
3.1 General ................................................................................................................... 8
3.2 Equipment Required............................................................................................... 8
3.2.1 Equipment Supplied....................................................................................... 8
3.2.2Equipment NotSupplied .................................................................................. 8
3.2.3AIMAnnuciator............................................................................................... 8
3.3MountingTrayInstallation ......................................................................................... 8
3.4 Static Port Connection ........................................................................................... 9
3.5 Electrical Installation .............................................................................................. 9
3.6 Calibration ............................................................................................................ 14
3.6.1 Equipment Required .................................................................................... 14
3.6.2 Calibration Procedures................................................................................. 15
3.6.3 Placarding .................................................................................................... 16
3.7 Continued Airworthiness...................................................................................... 16
List Of Illustrations
Figure 3-1 SAE5-35 Outline Dimensions (with tray) ...................................................... 9
Figure 3-2 J4/J5 Connector Wiring ............................................................................... 11
Figure 3-3 J4/J5 Connector Hood Assembly................................................................. 11
Figure 3-4 J4 Pinout ...................................................................................................... 12
Figure 3-5 J5 Pinout ...................................................................................................... 12
Figure 3-6 Interconnect To Popular Transponders........................................................ 13
Figure 3-7 Interconnect to Garmin & UPSAT GPS and MX20 .................................... 14
Figure 3-8 SAE5-35 Adjustment ................................................................................... 16
Figure 3-9 Gillham Grey Code Chart ....................................................................... 17-19
2

Section 1 General Description
1.1 INTRODUCTION
This manual describes the installation of the SANDIA aerospace SAE5-35 Altitude Data System. It
is intended for use by FAAcertified repair stations to install the SAE5-35 Altitude Data System and
includes both the mechanical and electrical installation information for the SAE5-35. Calibration and
checkout procedures are included. The installer should insure that all functions are operating accord-
ing to their intended purpose in their particular installation.
1.1.1 Product Description
The SAE5-35 is a solid state -1000 to 35,000 foot altitude data system that converts pressure altitude
into a digital output as set forth in the International Standard for SSR Pressure Altitude Transmis-
sion. The data output of the SAE5-35 is referenced to 29.92 inch HG (1013 Millibars). The SAE5-
35 has been designed to provide altitude data to GPS and TerrainAwareness Systems in addition to
Mode C Transponders. The SAE5-35 outputs Gillham Grey Code to the transponder and two inde-
pendent RS232 digital outputs that can be used by GPS or other systems requiring this format.
Additionally, the SAE5-35 includes SANDIA aerospace’s exclusiveAltitude In-flight Monitoring
(AIM) feature. With the addition of an optional panel mounted switch and annunciator the AIM
mode will monitor and advise the pilot if the aircraft deviates from a selected altitude.
1.2 TECHNICAL CHARACTERISTICS
1.2.1 Physical Characteristics
Width: 4.87” (5.11” with mounting tray)
Height: 1.06” (1.57” with mounting tray)
Depth: 4.74” (4.80” with mounting tray)
Weight: 0.7 lbs. (.86 lbs. with mounting tray)
1.2.2 OperationalCharacteristics
Operating Temp. -20o C to + 55oC
Altitude: 35,000 feet
Voltage: 11 - 32 Vdc
Current 1.0 amps maximum with heater on
<100 mA quiescent
Accuracy: +/- 50 feet Typical
Resolution: Grey Code 100’
RS232 10’
Burst Pressure 90 in Hg
Maximum Rate of Altitude Change: 12,000 Feet/Minute
3

1.2.3 Gillham Grey Code Outputs
a. 10 Bits available: D4, A4, A2, A1, B4, B2, B1, C4, C2, C1
b. Bit On Impedance: Less than 5 ohms
c. Bit Off Leakage: Less than 10uA
d. Maximum Current per bit: 20 mA
e. Minimum working current: 10 uA
f. Maximum voltage per bit: 50V
g. Minimum working voltage: 5V
h. Bit update rate: Less than 250 mS
i. Minimum strobe switching bandwidth: Greater than 10kHz
1.2.4 AIM Outputs
Maximum Lamp Current: 80 mA
Maximum offVoltage: 50V
1.2.5 Discrete Inputs
AIM SET, Strobe and RS232 Mode Select Inputs
Asserted: < 0.4 Vdc
Not Asserted: > 1.7 Vdc
Pull-up current: 150 uA
1.2.6 RS-232Outputs
There are two modes of operation for the RS232 outputs. The Data Mode pin, J5 pin 4 selects the
data formats.
1.2.6.1 Standard Mode
When the Mode pin (J5 pin 4) is open:
a. Baud: 9600
b. Data bits: 8
c. Stop bit: 1
d. Parity: None
e. Output rate: 1 +/- .2 seconds
f. Message length: 11 bytes
g. Altitude resolution: 10 foot
h. Works with Garmin and Trimble GPS
4 305186-00

5
1.2.6.2 Extended Mode
When the Mode pin (J5 pin 4) is grounded:
a. Baud: 1200
b. Data bits: 8
c. Stop bit: 1
d. Parity: None
e. Output rate: 1 +/- .2 seconds
f. Message length: 17 bytes
g. Altitude resolution: 10 foot
h. Temperature resolution: 1 degree C
i. For use with UPSAT MX20 and GPS receivers
1.2.7 Certification
TSO: C88a
Software: DO-178B Level C
Environmental: DO-160D(C1)CAA[(SM)(UF)]XXXXXXZBBBBTBXXXX

Environmental Qualification Form for the SAE5-35 Altitude Data System
NOMENCLATURE: SAE5-35, Altitude Data System
TYPE/MODEL/PART NO: SAE5 – 35 / 305154-00
TSO NUMBER: C88a
MANUFACTURER’S SPECIFICATION AN/OR OTHER APPLICABLE SPECIFICATION:
SAE5-35 INSTALLATION MANUAL P/N 305186-00
QUALIFICATION TEST PLAN, SAE5-35 ALTITUDE ENCODER. P/N AENC0051
MANUFACTURER: SANDIAAEROSPACE
ADDRESS: 5445 EDITH BLVD. NE, SUITE I ALBUQUERQUE, NM 87107
REVISION & CHANGE NUMBER OF DO-160: REV D, DATED JULY27 1997
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6 305186-00
DATE OF TEST: July 2000

Section 2 Installation Considerations
2.1 INTRODUCTION
The SAE5-35Altitude Data System simplifies installations that include GPS, TerrainAware-
ness Systems and other avionics that require RS232 altitude input information. The SAE5-35
provides standard Gillham Grey Code output on its 15 pin connector. Grey code is required
for interface to Mode C ATCRBS and Mode S transponders. Two independent RS232
outputs are provided on the nine pin connector. The SAE5-35 also incorporates SANDIA
aerospace’s exclusive Altitude In-flight Monitoring (AIM) feature that advises pilots if they
deviate from their selected altitude by more than one hundred feet. The AIM feature can be
installed by purchasing SANDIA aerospace’s optional annunciator/switch assembly, P/N
305217-00. Or the installer can supply his own switch and annunciator assembly(s). The
main 15 pin connector follows the standard encoder interconnect used by many manufactur-
ers. By following this convention, upgrading to the SAE5-35 is made easier. If another
manufacturers encoder is being replaced, it is important to check the wiring information
before plugging the existing connector into the SAE5-35. Both the Grey Code output and
each of the RS232 outputs have separate drivers. This ensures that a load on one line does
not load the other. Additionally, the RS232 output is available even if the enable line on the
Grey Code has not been enabled by the transponder.
The SAE5-35 does not require warm up unless the outside temperature is below 20 degrees
C. When warm up time is required, the internal heater is capable of warming the SAE5-35
from -20 degrees C to operating temperature in less than two minutes.
2.2 MOUNTING CONSIDERATIONS
The SAE5-35 can be mounted in any axis and either inside or outside the pressure vessel.
Mounting should allow for as short a pressure line as possible from the encoder to the altim-
eter. Be sure to allow an ample service loop on the cable to allow for calibration of the
SAE5-35
CAUTION: DO NOT mount the SAE5-35 in
the direct airstream or near either the hot or
cold air ducts.
2.3 COOLING
The SAE5-35 does not require external cooling.
7

3.1 GENERAL
The SAE5-35 is supplied with a mounting tray and solder type mating connectors. It is important
that proper solder techniques be observed in attaching wires to the mating connectors. Failure to do
so could result in a failure in the connection and cause intermittent or non operation of the SAE5-35.
Section 3 Installation Procedures
3.2 EQUIPMENT REQUIRED
3.2.1 Supplied
SAE5-35 System 705154-00
Includes: SAE5-35 Encoder 305154-00
SAE5-35 Installation Manual 305186-00
SAE5-35 Installation Kit 305216-00
15 Pin Mating Connector 305215
15 Pin Connector Hood 305208
9 Pin Mating Connector 305214
9 Pin Connector Hood 305207
MountingTray 305145
Knurled Holdown Nut 305189
3.2.2 Requiredbutnot supplied
Number 6-32 mounting screws
Staticportfitting
3.2.3 OptionalEquipment
AIMAnnunciator,InstallersuppliedorSandia Part Number307217-00
3.3 MOUNTING TRAY INSTALLATION
The mounting tray is mounted to the airframe using either three or four number 6-32 screws. The
mounting hole pattern for the SAE5-35 mounting tray contains five holes. For new installations, it is
recommended that the four corner holes be used to mount the SAE5-35 tray. The fifth hole has been
added to facilitate upgrades from other manufactures encoders. Refer to the SAE5-35 tray dimen-
sions in Figure 3-1 to determine if the hole pattern of the removed system match the hole pattern of
the SAE5-35 mounting tray.
8 305186-00

3.4 STATIC PORT CONNECTION
A standard 1/8 - 27 NPT brass fitting is provided on the front plate of the encoder for attaching to the
aircraft static air system. An adapter may be used to convert this to match the aircraft static plumb-
ing. When attaching the mating fitting, make sure that it is secure and free from leaks that can induce
errors in the static system. In installations where an existing encoder is being replaced, the existing
tubing and fittings should be examined for any damage or deterioration and replaced if necessary. To
reduce the likelihood of the brass fitting rotating while installing the static lines, a “D” shaped hole is
used to mount the brass fitting into the front panel. Upon completion of installation of the SAE5-35, a
Case Leak test is to be performed per FAR Part 43 Appendix E
NOTE: Since significant force can be applied to the encoder
during static fitting installation, dual wrench techniques are al-
ways recommended to avoid damage to the encoder.
3.5 ELECTRICAL INSTALLATION
The SAE5-35 is designed to operate from 11-32Vdc without any special wiring considerations.
Power can be supplied from the transponder’s switched A+ output, the transponder circuit breaker or
from the aircraft buss. If supplied from the aircraft buss, the line must be protected with a 2 amp fuse
Figure 3-1
SAE5-35 Outline Dimensions (with tray)
9
J4 J5