Wulfsberg FLEXCOMM II C-5000 User manual

REVISION HISTORY
Refer to the DCA and associated markups for a complete description of
the changes incorporated in a revision.
REV
DCA
DATE
DRAWN
CHECKED
APPROVED
PUBLISHED
A
*I.R.
04/01/91
B. Patt
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B
**
06/01/93
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C
W302
07/21/98
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D
W4507
05/31/05
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R Talken
SH & CE
E
W5685
03/31/08
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J. Jensen
L. Evans
F
W8457
08/21/09
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S. Wild
L. Andujo
G
W10755
12/20/10
C. Bretzing
A. Coburn
S. Elliott
L. Andujo
H
W12857
12/07/2012
Ken Marshall
Dan Brasher
Hank Schnieder
Linda Andujo
J
W13348
09/1/2013
Ken Marshall
Tammie Mallette
Robert Davis
Linda Andujo
K
W15839
04/29/2016
Ken Marshall
Jay Jensen
John Blasi
Linda Andujo
L
W18074
05/30/18
James Sneed
John Blasi
Jim Bachelor
06/11/18
M
W18800
02/19/19
*I.R. = Initial Release
** = Complete revision of Rev. A
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TEMPLATE 150-744545-01 REV. C
Chelton Avionics, Inc.
dba Wulfsberg Electronics Division
Prescott, AZ
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DOCUMENT TITLE
FLEXCOMM II
C-5000 (Non-Digital)
INSTALLATION MANUAL
SIZE
A
LRU
C-5000
DOCUMENT NUMBER
150-1355-000
REV
M
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2019.02.19 11:26:16
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Digitally signed by Heath Flor
Date: 2019.02.26 15:09:27
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Digitally signed by David Urban
Date: 2019.02.20 11:01:41
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2019-02-26
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FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 2
Installation
Manual
Engineering and Production by Wulfsberg Electronics,
A Cobham Avionics & Surveillance Group Company
Wulfsberg Electronics
FLEXCOMM II C-5000
(Non-Digital)
Manual Number 150-1355-000
Revision L

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 3
Chelton Avionics Inc., dba Wulfsberg Electronics Division, a Cobham Avionics & Surveillance Group
Company, hereafter referred to as Cobham Avionics, is located in Prescott, Arizona. For more than 25
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FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 4
Record of Revisions
Rev
No.
Rev
Date
Date
Inserted
By
Rev
No.
Rev
Date
Date
Inserted
By
A
04/01/91
B
06/01/93
C
07/21/98
D
05/31/05
E
03/31/08
F
08/21/09
G
12/20/10
H
12/12/12
J
09/17/13
K
05/12/16
L
06/11/18
M
See
“Published
on” stamp
on cover
page

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 5
TABLE OF CONTENTS
SUBJECT
Cover Page ................................................................................................................ 2
Record of Revisions ..................................................................................................... 4
Table of Contents ........................................................................................................ 5
SECTION 1 –INTRODUCTION
1. Components .............................................................................................................12
A. Communication Management Controller ...............................................................12
B. FLEXCOMM II.....................................................................................................12
C. FLEXCOMM I......................................................................................................13
D. Part Numbering..................................................................................................14
E. FCC Compliance .................................................................................................26
F. Special Airworthiness for Non-Aviation Transmitters ..............................................26
G. Instructions for Continued Airworthiness ..............................................................26
SECTION 2 –SYSTEM INSTALLATION
1. General ....................................................................................................................27
2. Sample Systems........................................................................................................27
3. Component Specifications ..........................................................................................29
A. C-5000 Communication Management Controller ....................................................29
B. FLEXCOMM II (RT-5000).....................................................................................30
C. RT-5000 Antennas..............................................................................................31
D. FLEXCOMM I......................................................................................................35
E. Miscellaneous Data Loading Cables and Software..................................................35
SECTION 3 –MECHANICAL INSTALLATION
1. General ....................................................................................................................36
2. Unpacking and Inspecting Equipment .........................................................................36
3. General Installation Requirements ..............................................................................37
A. Component Weights ...........................................................................................37
Continues…….

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 6
TABLE OF CONTENTS
SECTION 3 –MECHANICAL INSTALLATION (Continued)
4. Installation of Multipin Crimp Connectors ....................................................................38
A. Contacts and Crimp Tool Information ....................................................................38
B. Contacts and Insertion/Removal Tool Manufacturer Name and Address....................38
5. Installation of C-5000 ................................................................................................38
6. Installation of RT-5000 ..............................................................................................38
7. Installation of Antennas.............................................................................................40
A. AT-560 / AT-5000................................................................................................40
B. FC-5000..............................................................................................................40
C. AT-160 and AT-150..............................................................................................40
D. AT-550 ...............................................................................................................40
E. FC-550................................................................................................................40
F. AT-50 AND AT-51 ................................................................................................41
G. FC-50 .................................................................................................................41
H. AT-400 ...............................................................................................................41
I. AT-140 ...............................................................................................................41
J. Antenna Mechanical Installation ............................................................................42
K. Coax Installation Instructions................................................................................42
SECTION 4 –ELECTRICAL INSTALLATION
1. General ....................................................................................................................62
2. Wiring Considerations................................................................................................62
A. C-5000 System Interface Connector, P500 .............................................................63
B. C-5000 Serial Interface Connector to RT-5000 Transceiver, P501, P502, P503 ..........75
C. RT-5000 Transceiver Installation Wiring Diagram ...................................................80
D. C-5000 Communication Management Controller Installation .................................110
E. C-5000 Parallel Interface, RT-9600, RT-9600F, RT-7200 Transceivers ....................122
F. Special Options..................................................................................................127
Continues…….

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 7
TABLE OF CONTENTS
SECTION 5 –CONFIGURATION AND PROGRAMMING
1. Introduction ...........................................................................................................133
SECTION 6 –SYSTEM CHECKOUT
1. General ..................................................................................................................134
A. Terms, Definitions and Limitations.......................................................................134
2. System Checkout ....................................................................................................134
A. General ....................................................................................................134
B. Checkout Setup .................................................................................................135
C. Checklist ...........................................................................................................135
D. Checkout Procedure...........................................................................................135
3. Transmitter Tests....................................................................................................136
A. General.............................................................................................................136
B. Receiver Verification ..........................................................................................137
C. Encryption Verification .......................................................................................137
4. Installation Checkout Data Tables and Checklist.........................................................138
Transmitter Test Data Sheet ....................................................................................141
Receiver Test Data Sheet.........................................................................................143
SECTION 7- FLEXCOMM II RAMP TEST PROCEDURE
1. Introduction ...........................................................................................................145
2. Procedure...............................................................................................................145
3. Transmitter Tests....................................................................................................146
4. Receiver Verification................................................................................................147
5. GUARD Receiver Tests.............................................................................................148
6. Diagnostics.............................................................................................................148
Continues…….

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 8
TABLE OF CONTENTS
LIST OF FIGURES
1-1 C-5000 Part Numbering........................................................................................14
2-1 Single RT-5000 with Active Antenna ......................................................................27
2-2 Single RT-5000 with Passive Antenna ....................................................................27
2-3 Dual RT-5000 with Dual Mic/Headset.....................................................................27
2-4 Dual Transceiver, RT-5000 and Flexcomm I ...........................................................28
2-5 Dual Transceiver, RT-5000 and Parallel Flexcomm I Transceivers.............................28
2-6 Dual Transceiver with External Encryption .............................................................28
3-1 C-5000 Envelope Drawing, 154-031300 Rev. P .......................................................45
3-2 RT-5000 Envelope Drawing, 154-015525 Rev. N.....................................................46
3-2a RT-5000 Install Clearance Drawing........................................................................39
3-3 RT-5000 Horizontal Mount Tray Envelope Drawing, 154-016835 Rev. A....................47
3-4 RT-5000 Vertical Mount Tray Envelope Drawing, 154-016605 Rev. B........................48
3-5 Vibration Isolator Drawing, 246-017812 Rev. A ......................................................49
3-6 AT-560 Antenna Envelope Drawing, 121-040130 Rev. M .........................................50
3-7 AT-160 Antenna Envelope Drawing, 121-040129 Rev. K..........................................51
3-8 AT-5000 Antenna Envelope Drawing, 121-040045 Rev. G........................................52
3-9 AT-550 Antenna Envelope Drawing, 121-017850 Rev. J ..........................................53
3-10 AT-150 Antenna Envelope Drawing, 153-017822 Rev. G .........................................54
3-11 AT-50 Antenna Envelope Drawing, 121-016587 Rev. M...........................................55
3-12 AT-51 Antenna Envelope Drawing, 121-016796 Rev. K ...........................................56
3-13 AT-140 Antenna Envelope Drawing, 121-016584 Rev. G .........................................57
3-14 AT-400 Antenna Envelope Drawing, 121-016821 Rev. G .........................................58
3-15 FC-50 Antenna Envelope Drawing, 153-016586 Rev. E............................................59
3-16 FC-5000 Antenna Envelope Drawing, 153-040047 Rev. B ........................................60
3-17 FC-550 Antenna Envelope Drawing, 153-017851 Rev. E ..........................................61
4-1 Rear View of C-5000 ............................................................................................62
4-2 P500 Connector...................................................................................................63
4-3 C-5000 Standard Installation Wiring Diagram, 147-014995 Rev. G ...........................72
Continues…….

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 9
TABLE OF CONTENTS
LIST OF FIGURES (Continued)
4-4 P501/P502/P503 Connectors.................................................................................75
4-5 Connector J101 ...................................................................................................80
4-6 FC-50 / FC-550 / FC-5000 Connector J1.................................................................87
4-7 FC-50 / FC-550 / FC-5000 Connector J2.................................................................88
4-8 FC-50 / FC-550 / FC-5000 Connector J3.................................................................89
4-9 Flexcomm II System Interconnect Drawing, 152-140131 Rev. P ..............................90
4-10 C-5000 Parallel Interface (FLEXCOMM I) Connector P501, P502, P503....................110
4-11 Flexcomm I Transceiver Install Wiring Diagram, 147-014991 Rev. B .....................117
4-12 C-5000 Parallel Interface Connector P501, P502, P503..........................................122
4-13 Install Wiring Diagram (RT-9600, RT-9600F, RT-7200, C-5000),
147-014992 Rev. 4 ............................................................................................124
4-14 Dual C-5000/RT-5000 with Take_Control Block Diagram .......................................130
4-15 C-5000 Cloning Cable Wiring Diagram, 246-042755 Rev. B....................................131
4-16 KVL 3000 to DSUB 9-Pin Cable Wiring Diagram, 246-049082 Rev. A.......................132
LIST OF TABLES
1-1 RT-5000 Part Numbers.........................................................................................15
1-2 FLEXCOMM II Antenna Part Numbers ....................................................................15
1-3 RT-30 Part Numbers ............................................................................................16
1-4 RT-118 Part Numbers...........................................................................................16
1-5 RT-138 Part Numbers...........................................................................................16
1-6 RT-138F Part Numbers.........................................................................................17
1-7 RT-406F Part Numbers.........................................................................................18
1-8 RT-450 Part Numbers...........................................................................................18
1-9 RT-7200 Part Numbers.........................................................................................19
Continues…….

FLEXCOMM II
C-5000 (Non-Digital)
Installation Manual
150-1355-000 Rev. M
CONFIDENTIAL AND PROPRIETARY TO COBHAM
Page 10
TABLE OF CONTENTS
LIST OF TABLES (Continued)
1-10 RT-9600 Part Numbers.........................................................................................19
1-11 RT-9600F Part Numbers .......................................................................................20
1-12 Connectors Used .................................................................................................22
2-1 System Power Requirements ................................................................................29
3-1 Component Weights.............................................................................................37
4-1 System Interface Connector P500 .........................................................................64
4-2 C-5000 Serial Interface Connector to RT-5000 P501, 502, P503...............................75
4-3 RT-5000 Transceiver Connector J101 ....................................................................81
4-4 C-5000 Parallel Interface (FLEXCOMM I) Connector P501 or P502 or P503..............111
4-5 C-5000 Parallel Interface RT-9600(F), 7200 Connector P501, P502, P503 ...............123
6-1 RT-30 Transceiver Test Frequencies ....................................................................141
6-2 RT-138(F) Transceiver Test Frequencies ..............................................................141
6-3 RT-406F Transceiver Test Frequencies ................................................................141
6-4 RT-450 Transceiver Test Frequencies ..................................................................141
6-5 RT-5000 Transceiver Lo Split (29.7 to 399.999 MHz) Test Frequencies ...................141
6-6 RT-5000 Transceiver Hi Split (400 MHz to 959.999) Test Frequencies ....................142
6-7 RT-30 Transceiver Test Frequencies ....................................................................143
6-8 RT-138(F) Transceiver Test Frequencies ..............................................................143
6-9 RT-406F Transceiver Test Frequencies ................................................................143
6-10 RT-450 Transceiver Test Frequencies ..................................................................143
6-11 RT-5000 Transceiver Lo Split (29.7 to 399.999 MHz) Test .....................................144
6-12 RT-5000 Transceiver Hi Split (400 MHz to 959.999) Test Frequencies ....................144
Continues…….