Honeywell Bendix/King KY 196B Installation Manual

INSTALLATION MANUAL

KY 196B

VHF COMMUNICATIONS

TRANSCEIVER

MANUAL NUMBER 006--10570--0001

REVISION 1, JANUARY, 2000

WARNING

Prior to 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 International Inc. is prohib­ited. For further information contact the Manager, Technical Publications,
Honeywell International Inc., One Technology Center, 23500 West 105th
Street, Olathe, Kansas 66061. Telephone: [phone]

BENDIX/KING

KY 196B

VHF COMMUNICATIONS TRANSCEIVER

SECTION I

GENERAL INFORMATION

Paragraph Page

1.1 INTRODUCTION 1--1

1.2 DESCRIPTION OF EQUIPMENT 1--1

1.3 TECHNICAL CHARACTERISTICS 1--1

1.4 UNITS AND ACCESSORIES SUPPLIED 1--4

1.5 ACCESSORIES REQUIRED, BUT NOT SUPPLIED 1--5

1.6 LICENSE REQUIREMENTS 1--5

1.7 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 1--6

SECTION II

INSTALLATION

2.1 GENERAL INFORMATION 2--1

2.2 UNPACKING AND INSPECTING EQUIPMENT 2--1

2.3 EQUIPMENT INSTALLATION 2--1

2.3.1 AVIONICS COOLING REQUIREMENTS 2--1

2.3.2 MOUNTING RACK INSTALLATION 2--2

2.3.3 ANTENNA INSTALLATION 2--2

2.3.4 CABLE HARNESS AND CONNECTOR ASSEMBLY 2--2

2.3.5 KY 196B INSTALLATION 2--3

2.3.6 MOLEX TERMINAL INSTRUCTIONS 2--5

2.4 POST INSTALLATION CHECKS 2--7

SECTION III

OPERATION

3.1 GENERAL INFORMATION 3--1

3.1.1 TURN ON 3--1

3.1.2 TRANSMIT INDICATOR 3--1

3.1.3 MODES OF OPERATION 3--1

3.1.4 REMOTE FREQUENCY TRANSFER 3--3

3.1.5 REMOTE CHANNEL INCREMENT 3--3

3.1.6 DIM SELECT 3--3

3.1.7 DISPLAY ADJUST MODE 3--3

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TSO APPENDIX

ENVIRONMENTAL QUALIFICATION FORMS

Drawing No. Page

004--02170--0082 TSO--1............................................

LIST OF ILLUSTRATIONS

Figure Page

2--1 MOLEX TERMINALS AND TOOLS 2--4........................

2--2 HAND CRIMPER 2--5........................................

2--3 CRIMP JAWS 2--5...........................................

2--4 TERMINAL INSERTION 2--6..................................

2--5 HAND CRIMPER INSERTION 2--6............................

2--6 CRIMPING PRESSURE ADJUSTMENT 2--7....................

2--7 CONNECTOR ASSEMBLY 2--9...............................

2--8 OUTLINE AND MOUNTING DRAWING 2--11....................

2--9 INSTALLATION ASSEMBLY DRAWING 2--13....................

2--10 KY 196B INTERCONNECT 2--15

2--11 DUAL KY 196B INTERCONNECT DIAGRAM 2--17...............

2--12 KY 196B INTERCONNECT WITH KA 25A 2--19.................

2--13 KY 196B PIN FUNCTION AND LOCATION DIAGRAM 2--23.......

..............................

3--1 KY 196B VHF COMMUNICATIONS TRANSCEIVER 3--5.........

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BE NDIX / KING

KY 196B

VHF CO M M UNI CATI O NS T RANSCEI VER

SECTION I

GENERAL INFORMATION

1.1 INTRODUCTION

This m anual cont ains inf or m at ion r elat ive t o t he physical, m echanical, and elect r ical char act er ist ics
of t he BENDI X/ KI NG KY 196B VHF Com m unicat ions Tr ansceiver. I nst allat ion and oper at ing
pr ocedur es ar e also included. I nf or m at ion r elat ive t o t he m aint enance, alignm ent , and
pr ocur em ent of r eplacem ent par t s m ay be f ound in t he KY 196B M aint enance/ O v er haul M anual.

1.2 DESCRIPTION OF EQUIPMENT

The KY 196B VHF Com m Tr ansceiver consist s elect r ically of f ive sect ions: r eceiver, t r ansm it t er,
synt hesizer, display cir c uit r y, and t he m icr opr ocessor boar d. The KY 196B oper at es at 28VDC and
f eat ur es 16 Wat t s of t r ansm it t er power.

The KY 196B is available wit h 8. 33 KHz or 25KHz r eceiver select ivit y, diff used display lenses,
backlit bezel nom enclat ur e, and oper at ing r anges of 118. 000 t o 136. 9916 M Hz. See Par agr aph

1. 4 below f or descr ipt ions of specif ic f lavor s.
The KY 196B has t he c apabilit y of pr ogr am m ing up t o nine m em or y channel f r equencies f or lat er

r ecall. Channel f r equency inf or m at ion is st or ed in non -- volat ile m em or y so t he when t he r adio is
turned off and then back on, channel information is retained. Both units also have the capability
of remote transfer of Use and Standby frequencies, and remote recall of channel frequency
information.

1.3 TECHNICAL CHARACTERISTICS

SPECIFICATION CHARACTERISTIC

TSO COMPLIANCE:

Transmitter:

KY 196B (flavors --0101, --0201) TSO C37c, DO--186 Class 3

TSO C37c, DO--186a Class 5

Receiver:

KY 196B (flavors --0101, --0201) TSO C38c, DO--186 Classes C & D

TSO C38c, DO--186a Class E

ENVIRONMENTAL DATA:

PHYSICAL DIMENSIONS:

Height: 1.35 in (3.43 cm)

Width: 6.312 in (16.032 cm)

Depth (behind aircraft panel): 10.776 in (27.371 cm)

WEIGHT:

With rack

See TSO Appendix

3.2 lbs (1.45 Kg), ¦0.2 lbs (0.09 Kg.)

Without rack

MOUNTING: Panel mounted, no shock mounting

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3.0 lbs (1.36 Kg), ¦0.2 lbs (0.09 Kg.)

required

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BENDIX/KING

KY 196B

VHF COMMUNICATIONS TRANSCEIVER

TEMPERATURE RANGE:

POWER REQUIREMENTS:

KY 196B: 28VDC at 0.4A (Receive)

FREQUENCY RANGE: 118.000 MHz to 136.9916 MHz in

FREQUENCY STABILITY: 0.0005% from --20°Cto+55°C

DESIGN: All solid state, Printed circuit board

FCC ID: ASYKY196B

FCC EMISSION DESIGNATORS: 6K00A3E

TRANSMITTER

-- 2 0 °Cto+55°C with short time
operation at +70°C

6.5A (Transmit)

8.33 KHz mode.

118.000 MHz to 136.975 MHz in 25

KHz mode

and point to point wiring.

6K00A9W

POWER OUTPUT:

KY 196B: 16 Watts minimum

MODULA TION: 70% modulation capability with 98% limiting.

Less than 15% distortion at 70% modulation.

SIDETONE OUTPUT: Adjustable up to 100mW into 500Ω headphones

MICROPHONE: Standard carbon dynamic mic containing

transistorized preamp. Must provide 100mVRMS
into 100Ω load.

HARMONIC CONTENT: Greater than 60dB down from carrier.

HIGH TEMPERATURE PROTECTION: If the transmitter or modulator circuits become hot

enough to potentially hurt any components in the
transceiver, a protection circuit will automatically turn
down the transmitter power consumption and output
power to 4 Watts minimum.

DUTY CYCLE: 1 minute on, 4 minutes off

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KY 196B

VHF COMMUNICATIONS TRANSCEIVER

RECEIVER

RECEIVER SENSITIVITY: 2µV (hard) shall produce not less than 6dB S+N/N

with 1KHz tone modulated 30% (with compressor
disabled).

RECEIVER SELECTIVITY:

Class C, D (flavors --0101, --0201) 6dB bandwidth at not less than 8.0 KHz on each

side. 40dB bandwidth with no more than 17.0 KHz
on each side. 60dB bandwidth with no more than

22.0 KHz on each side.

Class E (flavors --0101, --0201) 6 dB bandwidth at not less than 2.778 kHz on

each side.
60 dB bandwidth at not more than 7.37 kHz on
each side.

RECEIVER OUTPUT: 100mW minimum into 500Ω minimum.

AGC CHARACTERISTIC: From 10 µV to 100,000 µV audio output will not

vary more than 3dB.

SQUELCH: Automatic squelch (internally adjustable

carrier--to--noise setting) with manual disable.

SPURIOUS RESPONSES AND CROSS
MODULA TION PRODUCTS: At least 80dB down.

INTERCOM INPUT: The mic is connected to the intercom input. The

receiver is operational and mic audio appears at
the audio output along with receive audio.
100mVRMS of mic audio into 100Ω is required
for 100mW output.

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KY 196B

VHF COMMUNICATIONS TRANSCEIVER

1.4 UNITS AND ACCESSORIES SUPPLIED

A. KY 196B VHF Comm Transceiver, PN 064--01084--XXXX, which is available in

the following flavors:

Receiver

PN

064--01084--0101

064--01084--0201

Some part numbers may not be currently available. Consult the
current Honeywell International Inc. catalog or contact your
Honeywell International Inc. representative for equipment
availability.

The 064--01084--0201 version has 5V lighting. Also, the bezel will be
removed since this version is used in common bezel applications
such as the CNI 5000.

B. KY 196B Installation Kit, PN 050--02600--0000, which contains the

following components:

PN

030--00101--0002 PANEL MOUNT PLUG 1.00

030--01094--0080 CONNECTOR KEYED 1.00

Selectivity

8.33 / 25 KHz

8.33 / 25 KHz

DESCRIPTION QTY

LENS

Diffused 118.000 to 136.9916MHz

N/A 118.000 to 136.9916MHz

NOTE

NOTE

FREQUENCY
RANGE

Page 1-4

030--01107--0031 CONNECTOR TERM 31T 1.00

057--02193--0001 DECAL COMM 1 1.00

057--02193--0002 DECAL COMM 2 1.00

089--02013--0037 NUT HEX 6--32 1.00

089--02051--0024 NUT SPEED U 6--32 4.00

089--02191--0022 NUT HEX ESNA 6--32 1.00

089--02353--0001 NUT CLIP 6--32 6.00

089--05903--0007 SCR PHP 4--40X7/16 2.00

089--05907--0008 SCR PHP 6--32X1/2 1.00

089--06012--0008 SCR FHP 6--32X1/2 6.00

089--08094--0030 WSHR FLT STD .446 1.00

089--08168--0002 WASHER WAVE 1.00

090--00019--0007 RING RTNR .438 1.00

091--00072--0002

CABLE CLAMP 2 1.00

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VHF COMMUNICATIONS TRANSCEIVER

1.5 ACCESSORIES REQUIRED, BUT NOT SUPPLIED

A. Communications antenna and cables.

For Installations which must meet the German Cetecom antenna conducted
radiation requirement, one of the following antenna must be used:

Manufacturer Part Number

Chelton

Dayton Granger VF10--108--2

Trivec--Avant Corp. 17--40--02W

Trivec--Avant Corp. 18--50--01

B. Headphones: 500Ω nominal impedance.

C. Microphone: Low impedance carbon or dynamic with transistorized preamp.

D. For 13.75V operation of the KY 196B a 14 to 28V converter such as the KGS

Electronics Model RB--125 or equivalent may be used. The RB--125 is available
from BENDIX/KING under PN 068--01016--0003.

21--38--1RF/36

1.6 LICENSE REQUIREMENTS

The transmitter, as installed in the aircraft, requires an Aircraft Radio Station License. This
license is obtaining by filing FCC Form 404, Aircraft Radio Station License Application, which
may be obtained from your local FCC Field Office. The KY 196B may be operated for up to 30
days without a station license after filing Form 404 while awaiting the receipt of the radio license
if a copy of FCC Form 404 is kept in the aircraft.

This equipment has been type accepted by the FCC and entered on their list of type accepted
equipment as Honeywell International Inc. KY 196B, and must be identified as Honeywell
International Inc. KY 196B on FCC Form 404.

CAUTION

THE VHF TRANSMITTER IN THIS EQUIPMENT IS
GUARANTEED TO MEET FEDERAL COMMUNICATIONS
COMMISSION ACCEPTANCE OVER THE OPERATING
TEMPERATURE RANGE ONLY WHEN AN HONEYWELL
INTERNATIONAL INC. CRYSTAL IS USED IN THE
STABILIZED MASTER OSCILLATOR.

USE OF OTHER THAN AN HONEYWELL INTERNATIONAL
INC. CRYSTAL IS CONSIDERED AN UNAUTHORIZED
MODIFICATION AND MAY VOID THE WARRANTY.

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KY 196B

VHF COMMUNICATIONS TRANSCEIVER

The Federal Communications Commission requires that the operator of the transmitter of this
equipment hold a Restricted Radio Telephone Operator Permit (FCC Form 753) or higher class
license. A permit may be obtained by a US citizen from the nearest field office of the FCC; no
examination is required.

1.7 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

The instructions for continued airworthiness given in the TC or STC approvals for this product
supplements or supercedes the instructions for continued airworthiness in this manual.

Most Honeywell International Inc. products are designed and manufactured to allow ”on condition
maintenance.” On condition maintenance is described as follows; There are no periodic service
requirements necessary to maintain continued airworthiness. No maintenance is required until the
equipment does not properly perform it’s intended function. When service is required, a complete
performance test should be accomplished following any repair action. Consult the appropriate unit
Maintenance/Overhaul Manual for complete performance test information.

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KY 196B

VHF COMMUNICATIONS TRANSCEIVER

SECTION II

INSTALLATION

2.1 GENERAL INFORMATION

This section contains suggestions and factors to consider before installing the KY 196B. Close
adherence to these suggestions will assure more satisfactory performance from the equipment.

2.2 UNPACKING AND INSPECTING EQUIPMENT

Unpack the equipment carefully and inspect each item for evidence of damage incurred during
shipment. If a damage claim must be filed, save the shipping container and all packing materials
to substantiate your claim. The claim should be filed with the transportation company as soon as
possible. The shipping container and packing material should be saved in any case in the event
that storage or reshipment of the equipment is necessary.

2.3 EQUIPMENT INSTALLATION

The KY 196B installation will conform to standards designated by the customer, installing agency,
and existing conditions as to the unit location and type of installation. However, the following
suggestions should be considered before installing the KY 196B. The installing agency will supply
and fabricate all external cables. The connectors required are supplied by Honeywell International
Inc.. Interconnect diagrams are included in this manual as Figures 2--10 through 2--12. Refer to
table below for compatible installations.

Tabl e 2-- 1

Current Installation -- -- >

KY196B

*1 Display brightness controlled by dimmer bus not photocell.
*2 Button/Bezel backlighting not operative.
*3 If installation utilizes external audio amplifier.

NOTE: 064--01084--0201 is not compatible with other KY 96A/196A/197A installations, due to the

5 volt panel lighting and Bezel difference.

Use good quality stranded wire with at least 600V insulation that will
not support a flame.

2.3.1 AVIONICS COOLING REQUIREMENTS FOR PANEL MOUNTED EQUIPMENT

The most important contribution to improved reliability of avionics equipment is to limit the
maximum operating temperature of each unit. While modern designs consume less total
energy, the heat dissipated per unit volume (Watts/cubic inch) remains much the same due
to contemporary high density packaging techniques. While each individual unit may or may
not require forced air cooling, the combined heat generated by several units operating in

KY--Series Radio Installation compatibility

KY 96A KY 97A KY 196 KY 196A KY 197 KY 197A

YES *1 *3 NO YES *2 YES

NOTE

NO NO

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KY 196B

VHF COMMUNICATIONS TRANSCEIVER

a typical panel or rack can significantly degrade the reliability of the equipment if provisions
for adequate cooling are not incorporated in the initial installation.

2.3.2 MOUNTING RACK INSTALLATION A. The KY 196B is mounted rigidly in the aircraft panel. Select a position in the panel

that is not too close to any high external heat source. Remember to allow adequate
space for installation of cables and connectors. Avoid sharp bends and placing the
cables too near the aircraft control cables.

B. When installing two or more panel mounted units in a stack, the mounting trays shall be

spaced 0.050 inches (0.127 cm) apart. Current production mounting trays have 0.025
inch (0.064 cm) dimples built in to top and bottom and both sides so that the trays will
automatically be spaced properly.

C. Refer to Figure 2--8 for the KY 196B mounting dimensions. Mark and cut the

mounting holes.

D. Secure the mounting rack to the instrument panel per Figure 2--8. The rear mounting

bosses should be attached to the airframe by means of support brackets.

2.3.3 ANTENNA INSTALLATION

A conventional 50Ω vertically polarized comm antenna is required with the KY 196B. Vertical bent
whip antennas are not recommended. Wideband comm antennas provide efficient operation over
the comm band. Antennas should be installed per manufacturer’s recommendations. Additional
recommendations are as follows:

A. Mount antenna on a flat metal surface or install a ground plane at least 18 inches square.
B. The antenna should be well removed from any projections and the engine(s) and

propeller(s). Also, for satisfactory operation, the antenna isolation between a
communications transmitter antenna and a nav receiver antenna, as well as between
dual comm antennas, should be a minimum of 30dB. VHF antennas mounted on top
and bottom have approximately 30dB isolation. A horizontally polarized nav antenna
and a vertically polarized comm antenna will have practical values from 10 to 30dB.

C. If both comm antennas must be top mounted or both bottom mounted, antenna isolation

between comms may not be adequate to prevent reradiation. In single audio panel
installations, reradiation can be prevented by use of the XMIT--REC interlock. In dual
audio panel installations where simultaneous operation of both comms is desired, the
XMIT--REC interlock is not recommended.

2.3.4 CABLE HARNESS AND CONNECTOR ASSEMBLY

The KY 196B uses a special connector that mates directly with the printed circuit board
inside the unit. Assembly of the connector is as follows:

A. Contact Terminal Assembly using Molex Crimper (See Figure 2--2)

1. Strip each wire 5/32” for contact terminal, PN 030--01107--00XX. Note: The last two
digits of the part number indicates the number of terminals required.

2. Place the conductor tab section of a contact terminal on the appropriate anvil of the
hand crimping tool. Close the crimper until the terminal is held lightly in place.

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KY 196B

VHF COMMUNICATIONS TRANSCEIVER

3. Insert the stripped conductor into the contact until the insulation is even with the side
of the crimper facing the operator, the conductor hits the crimper’s wire stop, or the
insulation contacts the crimpers step--jaw, depending on the type of crimp tool being
used.

4. Squeeze the crimping tool’s handles until the crimp jaws are fully closed or until a
sufficient crimp is obtained. With a step--jaw type crimper, the contact terminal will
have been crimped to both the insulated and bare sections of the conductor.
If single--jaw crimpers are being used, move the contact terminal/conductor
assembly to locate the terminal’s insulation tabs on the anvil of the crimp tool. Crimp
again until the jaws are fully closed or a sufficient crimp is obtained to the insulation.

B. Contact Insertion into Molex Connector Housing
After the contact terminals have been installed on the wiring harness, the contact terminals

can be inserted into the proper location in the connector housing (PN 030--01094--0080).
The terminal cannot be inserted upside down. Be sure to push the terminal all the way in
until a click can be felt or heard. The self--locking feature can be tested by gently pulling
on the wire.

C. Location of Polarizing Key in Housing
Prior to insertion of connector into rear of unit, check polarizing key position between

contacts 8 and 9. Refer to Figure 2--9 to check correct position of polarizing key.
D. Extraction of Contact from Molex Connector

1. Slip the flat narrow blade of a Molex HT--1884 contact ejector tool,
PN 047--05099--0001, under the contact on the mating side of the connector. By
turning the connector upside down one can see the blade slide into the stop.

2. When the ejector is slid into place, the retaining tab of the contact is raised, allowing
the contact to be removed by pulling moderately on the lead.

3. Neither the contact or position is damaged by removing a contact; however, the
contact should be visually checked before reinstalling to be certain that retaining tab
”A” extends as shown in Figure 2--1 for retention in connector.

E. Coax Connector
Refer to Figure 2--7 for instructions for mounting the right angle coaxial BNC connector to

the coax cable. Install the connector into the mounting rack.

2.3.5 KY 196B INSTALLATION

A. Looking at the top of the unit, make sure the front lobe of the hold--down device is in a
vertical position.

B. Slide the unit into the mounting rack until the front lobe touches the mounting rack.
C. Insert a 3/32” Allen wrench through the hole in the front panel to engage the locking

screw. Turn clockwise until the rear lobe engages the mounting rack. Continue turning
until the unit is secure in the mounting rack. DO NOT OVERTIGHTEN.

D. To remove the unit turn the locking screw counterclockwise, using a 3/32” Allen wrench,

until the unit disengages from the mounting rack. Pull the unit out of the mounting rack
by pulling on the indentations on each side of the unit’s bezel.

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