Apollo SL40 Field Maintenance Manual
Apollo
Model SL40
VHF COMM Transceiver
Field Maintenance Manual
PRELIMINARY
April, 1997
Draft 3
560-1014-00
1997 by II Morrow Inc. All rights reserved.
Printed in the USA
No part of this document may be transmitted, reproduced, or copied in any form or by any means
without the prior written consent of II Morrow Inc. Due to II Morrow’s commitment to
constantly improve the quality and performance of our products, information contained in this
document is subject to change without notice.
II Morrow and Apollo are registered trademarks of II Morrow Inc.
II Morrow Inc. 2345 Turner Rd. SE
PO Box 13549 Salem, OR 97302
Salem, OR 97309 USA
Phone (503)581-8101
1-800-525-6726
In Canada 1-800-654-3415
FAX (503)364-2138
H
ISTORY OF REVISIONS
Revision Date Description
-- 4/8/97 Draft 3.
O
RDERING INFORMATION
To receive additional copies of this publication, order part #
COMM Transceiver Field Maintenance Manual.
R
EFERENCE PUBLICATIONS
Following are other publications referenced in this guide.
IPC 610A Acceptability of Electronic Assemblies
560-0956 Apollo Model SL40 VHF COMM Transceiver Installation Manual
560-1014,
Apollo SL40 VHF
N
OTES
Table of Contents
T
ABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................1
A
BOUT THIS MANUAL
A
POLLO
F
EATURES
R
EGULATORY COMPLIANCE
H
ANDLING CONSIDERATIONS
O
THER TOOLS AND EQUIPMENT
SL40 D
.........................................................................................................................................1
ROTECTION
ESD P
OMPONENT HANDLING
C
HIPPING CONSIDERATIONS
S
OOLS
T
....................................................................................................................................................................... 3
EST EQUIPMENT
T
......................................................................................................................1
ESCRIPTION
.............................................................................................................1
.............................................................................................................2
...........................................................................................................2
..................................................................................................................................................... 2
............................................................................................................................................ 3
....................................................................................................................................... 3
.......................................................................................................3
...................................................................................................................................................... 3
SECTION 2 - TROUBLESHOOTING.......................................................................................5
O
VERVIEW
ESD S
P
RELIMINARY CHECKOUT
S
YSTEM FUNCTIONS
OFTWARE VERSION DISPLAY
S
IGNAL STRENGTH DISPLAY
S
UDIO NOISE LEVEL DISPLAY
A
EADPHONE LEVEL DISPLAY AND ADJUSTMENT
H
NTERCOM SQUELCH THRESHOLD DISPLAY AND ADJUSTMENT
I
NTERCOM AUDIO LEVEL DISPLAY AND ADJUSTMENT
I
IDETONE LEVEL DISPLAY AND ADJUSTMENT
S
ASE STATION LOCKOUT MODE DISPLAY AND ADJUSTMENT
B
T
EST MODE OPERATION
EST MODE ACCESS
T
ENERAL OPERATION
G
EST MODE PAGE
T
ISPLAY TEST FUNCTION
D
ONTROLS TEST FUNCTION
C
T
EST SETUP
E
QUIPMENT TESTS
........................................................................................................................................5
AFE WORK AREA REQUIREMENTS
.........................................................................................5
.................................................................................................................5
.........................................................................................................................6
................................................................................................................................... 6
...................................................................................................................................... 6
................................................................................................................................... 6
...................................................................................................... 7
................................................................................. 7
.............................................................................................. 7
.......................................................................................................... 7
................................................................................... 8
...................................................................................................................9
................................................................................................................................................. 9
............................................................................................................................................... 9
..................................................................................................................................................... 9
.......................................................................................................................................... 9
.................................................................................................................................... 10
....................................................................................................................................10
..........................................................................................................................12
TRANSMITTER...........................................................................................................................13
RANSMITTER PERFORMANCE
T
RANSMITTER FREQUENCY ERROR
T
RANSMITTER POWER MEASUREMENT
T
RANSMITTER MODULATION
T
RANSMITTER
T
RANSMITTER AUDIO DISTORTION
T
SIGNAL TO NOISE RATIO
SNR (
................................................................................................................................13
......................................................................................................................... 13
................................................................................................................... 14
................................................................................................................................... 15
)........................................................................................................ 16
........................................................................................................................... 17
RECEIVER....................................................................................................................................17
ECEIVER PERFORMANCE
R
SPEAKER AUDIO TEST...................................................................................................................................... 18
RECEIVER SENSITIVITY................................................................................................................................... 19
U
NIT DISASSEMBLY / REASSEMBLY
ISASSEMBLY
D
EASSEMBLY
R
......................................................................................................................................................... 20
.......................................................................................................................................................... 21
....................................................................................................................................... 18
................................................................................................20
Apollo SL40 Field Maintenance Manual
i
Table of Contents
R
EPLACEABLE COMPONENTS
OMPONENT LISTING
C
EPLACEMENT POLICY
R
ACKAGING FOR SHIPMENT
P
C
ONTACTING THE FACTORY FOR ASSISTANCE
...............................................................................................................................................22
............................................................................................................................................22
......................................................................................................... 22
.....................................................................................................................................22
................................................................................ 22
SECTION 3 - CHECKOUT PROCEDURES .......................................................................... 25
G
ENERAL
S
ERVICE VERIFICATION
F
UNCTIONAL CHECKOUT
D
C
RANSMITTER TESTS
T
R
....................................................................................................................................... 25
.................................................................................................................. 25
................................................................................................................ 25
ISPLAY CHECK
ONTROLS TEST
ECEIVER TESTS
......................................................................................................................................................25
......................................................................................................................................................25
...............................................................................................................................................25
.....................................................................................................................................................25
APPENDIX A - TEST DATA LOG .......................................................................................... 27
P
OST INSTALLATION CHECKOUT
S
IDETONE LEVEL ADJUSTMENT
F
LIGHT TEST CHECK
...................................................................................................................... 27
.................................................................................................... 27
...................................................................................................... 27
LIST OF TABLES
T
ABLE
1 R
EPLACEABLE COMPONENTS
.......................................................................................... 22
LIST OF ILLUSTRATIONS
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
1 SL40 F
2. T
3. E
4. T
5. R
6. C
RONT PANEL
EST SETUP DIAGRAM
QUIPMENT CONNECTION
RANSMITTER TEST SETUP
ECEIVER TEST SETUP
OM MAIN BOARD OUTLINE
........................................................................................................ 2
................................................................................................... 11
.............................................................................................. 11
............................................................................................ 14
.................................................................................................. 19
......................................................................................... 20
ii Apollo SL40 Field Maintenance Manual
Introduction
S
ECTION
A
BOUT THIS MANUAL
1 - I
NTRODUCTION
This manual provides performance checkout instructions, troubleshooting instructions to the
board level, disassembly and reassembly procedures, and test procedures to verify that the unit
is once again operational. It is intended for use by persons certified by the Federal Aviation
Administration (FAA) to repair aircraft communication devices.
Section 1
Provides an
introduction
to the SL40 unit, details handling and shipping
considerations for the components, and lists required tools and test equipment.
Section 2
Includes all
troubleshooting
procedures, test setups, disassembly/reassembly, and
identifies replaceable components.
Section 3
Includes
checkout procedures
to ensure that repairs have been properly
completed and unit is fully serviceable
Appendix A
A
POLLO
Includes post repair
SL40 D
ESCRIPTION
test data log
sheets.
The Apollo SL40 is a 760 channel VHF Comm transceiver. It is one member of the Apollo
slimline series which includes the SL40 Comm, the SL50 GPS, and the SL60 GPS/Comm.
F
EATURES
The features of the SL40 Comm include:
•
760 channels
•
Frequency range of 118.000 to 136.975 MHz
•
Active and standby frequency display
•
16 character high-intensity alphanumeric LED display
•
Automatic display intensity
•
Back-lit buttons
•
Transmit status indicator
•
Frequency memory and recall functions
−
from remote source
−
eight last used
−
eight user stored
•
Weather channels
•
Frequency monitor function
•
Built-in intercom function
•
Stuck mic time-out
•
Two microphone inputs
•
Internal non-volatile memory - no battery required
•
Full range input supply voltage
•
12 watt audio amplifier
Apollo SL40 Field Maintenance Manual
1
Introduction
Figure 1 SL40 Front Panel
R
EGULATORY COMPLIANCE
The Apollo SL40 is designed and tested to meet the following TSOs:
FAA TSO-C37d for transmit
FAA TSO-C38d for receive
FAA TSO-C128 for unintentional transmission (stuck mic)
The Apollo SL40 complies with the FCC requirements specified in:
CFR 47, Part 87, Aviation Services, Subpart D, Technical Requirements
CFR 47, Part 15, Radio Frequency Devices, Subpart B, Unintentional Radiators
The Apollo SL40 software is designed and tested to RTCA/DO-178B, level C.
Note:
Unauthorized changes or modifications to the SL40 may void the compliance to
required regulatory agencies and authorization for continued equipment usage.
H
ANDLING CONSIDERATIONS
ESD P
ROTECTION
The case on the SL40 is designed to protect the components from mechanical damage and
also provides protection from damage due to electrostatic discharge. Open the case only
when the unit is in an ESD safe work area. Observe proper ESD techniques when
working on the unit.
2 Apollo SL40 Field Maintenance Manual
Introduction
C
OMPONENT HANDLING
The SL40 contains electrostatic discharge sensitive (ESDS) components. Care must be
taken when handling these devices to prevent damage. Special precautions for ESD work
areas are detailed in ESD Safe Work Area Requirements, Page 5. Both you and the work
surface must be properly grounded before handling the SL40 components. If moving the
SL40 components from one area to another, they must either be reinstalled in the SL40
case or placed in an anti-static bag.
S
HIPPING CONSIDERATIONS
All SL40 components must be returned to the factory in anti-static packaging equivalent
to that used to ship the components from the factory. Save the packaging from the
replacement components to use when returning the failed component. Packaging
instructions are provided on Page 22. If you have questions regarding shipment of the
SL40 components, contact the II Morrow Service Department. Information on how to
contact the factory is provided on Page 22.
O
THER TOOLS AND EQUIPMENT
The following tools and test equipment (or equivalent) are required to properly evaluate
and test the SL40. All test equipment must be calibrated before performing the test
procedures in this manual.
T
OOLS
A 3/32” hex tool is required to remove the SL40 from the mounting frame in the aircraft.
A #2 Phillips screwdriver is required for disassembly
T
EST EQUIPMENT
a. Power Supply:
HP6433B DC Power Supply (0-36 V 0-10A) or equivalent
b. RF Signal Generator:
HP8920 RF Communications Test Set or equivalent
c. Multimeter
FLUKE 8010A Digital Multimeter or equivalent
d. Test interface
Refer to Figure 2 for the Test Interface schematic and SL 40 transceiver setup.
Apollo SL40 Field Maintenance Manual
3
Introduction
N
OTES
4 Apollo SL40 Field Maintenance Manual
Troubleshooting
S
ECTION
This section provides information to assist in isolating problems with the SL40. Where
required, detailed drawings of test setups are provided. The specified test equipment is a
recommendation based on the equipment used to test the SL40 during manufacture and
factory service. Alternate, but equivalent, equipment may be substituted if the recommended
equipment is not available.
O
VERVIEW
Field maintenance of the SL40 is limited to replacement of the SP96 Com Display Board
and the VHF Com Main board.
ESD S
The SL40 circuit boards contain electrostatic discharge sensitive (ESDS) components. To
prevent damage to the ESDS components, the circuit boards must be removed from the
SL40 and handled in an ESD safe work area only. The work area must comply with the
requirements of IPC 610A or other equivalent document. At a minimum, observe the
following the following precautions when handling SL40 components.
Both you and the work surface must be properly grounded before handling the SL40
components. If moving the SL40 components from one area to another, they must either
be reinstalled in the SL40 case or placed in an anti-static bag.
2 - T
ROUBLESHOOTING
AFE WORK AREA REQUIREMENTS
P
RELIMINARY CHECKOUT
Perform the following tests before removing the SL40 from the aircraft to determine if
the problem is in the SL40 or the aircraft.
Transmission and reception range is normally not a problem in aircraft due to the aircraft
height above terrain. Poor reception range that can be traced to aircraft noise or antenna
performance is usually repairable.
The SL40 has a number of “System Functions” to assist in isolating Comm problems.
Two of these features assist the operator or service personnel, in evaluating the aircraft
communication environment: Signal Strength Display
Display (
can give the appearance of a malfunctioning radio. If the system functions fail to pinpoint
or correct a Comm problem remove the SL40 from the aircraft and refer to the Equipment
Test procedures on Page 12 for bench testing. A built in Display test function allows
isolation of Com Display board malfunctions with the SL40 mounted in the aircraft. If a
problem is isolated to the SL40 (Com Display board or Com Main board) refer to the
Disassembly procedures on Page 20 for instructions on removing and replacing the
malfunctioning component.
NOISE
). Additionally, there are several adjustments, which if improperly set,
(RFLVL)
and Audio Noise Level
Apollo SL40 Field Maintenance Manual
5
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