ionion is intended for dzus mount (or similar) installations. if you are unsure of the installation...

ION Installation Manual Rev. 1.6

Churchill Navigation Support ● Phone: 720.744.3300 ● E-mail: [email protected] 2

Rev Number

Description Date

1.0 1.1 1.2

1.3 1.4 1.5 1.6

Original document release Minor content revisions, updated installation drawings Audio information, updated installation drawings, and updated text description based on new installation drawings. Added change tracking (black lines in margin) Minor text updates Updated audio pin-outs, Installation diagram supplement added Added additional specifications for analog video Grounding requirements updated, misc. other updates

NOV 2015 DEC 2015 JUN 2016

SEP 2016 DEC 2016 JAN 2017 JUN 2017

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: [email protected] 3

Table of Contents

About this Manual ............................................................................................................... 4

Product Guarantee & Warranty Information ........................................................................ 4

Section 1: Specifications ....................................................................................................... 5 1.0 Description ........................................................................................................................... 5 1.1 Design Characteristics .......................................................................................................... 5

Section 2: Installation Guidelines ......................................................................................... 8 2.0 Description ........................................................................................................................... 8 2.1 Equipment Packaging ........................................................................................................... 8 2.2 Required Tools ..................................................................................................................... 8 2.3 Installation ........................................................................................................................... 9

Section 3: Aircraft Post-Installation Testing Procedures ...................................................... 14

Section 4: Installation Diagrams .......................................................................................... 17


Notice:

The information contained in this document is considered confidential and proprietary to Churchill Navigation. Neither the document nor the information contained therein should be disclosed or reproduced in whole or in part, without express written consent of Churchill Navigation. Changes or modifications not expressly approved by Churchill Navigation could void the user’s authority to operate the equipment. Non-Churchill Navigation part numbers referenced in this manual are not maintained by Churchill Navigation and may be subject to change without notice. All information depicted in this manual, including hardware and software names, versions, and part numbers, is subject to change and may not be up to date.

About this Manual This manual describes the physical, mechanical, and electrical components, as well as instructions for the installation of the Churchill Navigation ION. Every effort has been made to make this document as complete and accurate as possible.

The following symbols for warnings, cautions, and notes are used to throughout this manual.

Warning

A warning symbol denotes an item where a potential hazard capable of producing injury to personnel or destruction of equipment exists if the approved procedure is not followed.

Caution

A caution symbol denotes an item where, if not followed, damage to equipment or degradation of mission capability can occur.

Note

The note symbol is used to identify important information for installers / operators. While not directly related to safety or protection of equipment from damage, the note symbol identifies information to which attention should be paid during the installation and/or operation of the equipment.

Product Guarantee & Warranty Information For details about the Churchill Navigation ION warranty, please see the Terms and Conditions page available at www.churchillnavigation.com/agreement

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Section 1: Specifications

This document contains information that was current as of the printing of this manual. To obtain always up-to-date installation drawings, ICDs, and much more, visit: www.churchillnavigation.com/specifications

1.0 Description This section contains information concerning the physical characteristics and technical specifications of the Churchill Navigation ION video recorder.

1.1 Design Characteristics ION is a compact, solid-state DZUS mounted video recorder. ION offers simultaneous recording of two channels of HD-SDI video, one channel of analog video, audio, and metadata. Video is saved to removable USB or SD media for easy transport and hand-off. A full-color, backlit LCD display allows operators to review recorded clips on the go and even perform playback while recording.

1. Backlit, full-color, 2.15 in [54.61 mm] diagonal LCD screen 2. Backlit REC button 3. Backlit Mute button 4. Control knob (inner knob, outer knob, and push-button operation) 5. SD media (2x) 6. USB 3.0 (2x) 7. Fault light 8. CMOS Battery access tray (located on the bottom of the enclosure) *

* CMOS battery access tray included on ION hardware revision 2.8 and higher.

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Specifications

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4 6 5


1.2 Technical Characteristics & Specifications

Specification Characteristic

Product Designation/Description ION Video Recorder

Physical Dimensions Height at bezel: 1.875 in [47.63 mm] Width at bezel: 5.75 in [146.05 mm] Length (Enclosure depth): 7.0 in [177.8 mm] Overall depth, front knob to back of enclosure, excluding connectors: 8.32 in [211.33 mm]

Weight 2.6 lbs ± .05 lbs [1.18 kg ± .02 kg]

Display type / dimensions / resolution

Backlit LCD, 2.15 in [54.61 mm] diagonal Native 320 x 240 pixel resolution NVIS Class A compliant / NVIS class B compatible

Environmental Qualifications DO-160 Qualified

Operating Temperature Range -20°C to +70°C

Maximum Operating Altitude +45,000 feet [+13,716m]

Power: Input Voltage Input Current Power consumption

28VDC 4A on 28VDC (normal operating range) 112W (maximum)

Circuit Breaker Requirement Minimum 7.5 amp rated

Connection Types, Protocols, and Standards

LEMO (1x) J1 – Power/GPIO LEMO (1x) J2 – Ethernet LEMO (1x) J3 – Misc. (USB, ARINC 429, Audio) LEMO (1x) J4 – Serial port (RS232, RS422)

BNC J5, J6, J7 – HD-SDI 1 & HD-SDI 2 video in / HD-SDI video out

BNC J8, J9, J10 – Analog in Wi-Fi compatibility – 802.11ac

Video-in Support 2x HD-SDI inputs - Single channel, 3G-SDI (1080p60) input supported

1x Analog video input (CVBS, Y/C, YPbPr, & RGB)

Video-out Support 1x HD-SDI output - 3G-SDI (1080p60) output supported

Specifications


Video-out Supported Resolutions 720p (50 fps), 720p (60 fps), 1080p (25 fps), 1080p (30 fps)

1080p (60 fps), 1080i (50 fps), 1080i (60 fps)

Metadata Standard KLV MISB/STANAG 4609 compliant

Video Recording Codec H.265 (HEVC) – Skylake processor models only H.264 (MPEG-4) H.262 (MPEG-2)

Audio-in Support L/R channel in

Audio-out Support L/R channel out

Specifications


Section 2: Installation Guidelines

2.0 Description This section contains information and instructions for the unpacking and correct installation of the Churchill Navigation ION video recorder.

2.1 Equipment Packaging

Prior to installation, carefully inspect both the ION unit and the supplied power connector. Note any damage that may have occurred in transit and contact the parcel carrier if necessary to file a claim. Otherwise, check that all items listed below are present prior to proceeding with the installation. Report any missing items to your supplier.

- (1) ION - (1) ION power connector (p/n FGN.1M.308.XLCT) - (2) SD Cards (32GB each) - Product manuals and guides

It is recommended that you retain all original packaging for purposes of easy returns due to damage or warranty claims.

All other connectors are available for purchase from Churchill Navigation or direct from the manufacturers themselves. Additional information is provided in section 2.3 of this guide. If you have purchased additional hardware, such as the ION Connector Kit, from Churchill Navigation, please take a moment to inspect the condition of those connectors as well prior to starting the installation process.

2.2 Required Tools You will need the correct crimping tool for the connectors selected. A few examples are listed below and are available from Churchill Navigation or from their respective manufacturers.

BNC Connectors:

Application Connector: Crimp Die: 75ohm BNC plug for PICWire V73263 PicWire P/N 190712 M22520/5-41 75ohm BNC plug for RG59 Amphenol P/N 112123 .255/.213/.068 75ohm BNC plug for RG179 Amphenol P/N 112133 .178/.128/.068

All LEMO Connectors:

Crimp Tool Pin Positioner Pin Extractor DPC.91.701.V DCE.91.070.5MVC DCF.93.070.4LT

Installation


2.3 Installation ION is intended for DZUS mount (or similar) installations. If you are unsure of the installation location, please contact Churchill Navigation.

To ensure adequate airflow to the unit, Churchill Navigation recommends a minimum of 100mm between the back of the ION and any adjacent surface.

The minimum ION installation requires 28VDC power and at least one type of supported video input. Additionally, some operators may wish to include audio-in as a part of their basic setup. The corresponding Installation Manual sections required for minimum operation as described above are:

1) Power – Sections 2.3.1, 2.3.2, and 2.3.3.1 2) Video – Section 2.3.3.5 (HD-SDI) and Section 2.3.3.6 (Analog) 3) Optional audio-in – Section 2.3.3.3

Support for these as well as all other inputs and features are described in detail in the following sections of this guide.

2.3.1 Voltage Requirements ION operates on 28-volt DC power and consumes a maximum of 112 watts (4 amps on 28VDC). Churchill Navigation recommends using a minimum 7.5-amp circuit breaker.

2.3.2 Ground Requirements ION IS CASE-GROUNDED THROUGH THE DZUS MOUNT. If the DZUS mount is not directly grounded to the chassis, use a minimum of 16-gauge wire to ground the DZUS mount prior to ION operation. EXPOSED ALUMINUM IS CHROMATED. DO NOT CHEMICALLY COAT OR COVER WITH NON-CONDUCTIVE MATERIAL. ALL GROUND PINS EXCEPT 28V RETURN ARE GROUND CONTINUOUS TO CASE.

Failure to properly ground the ION unit may result in damage to the ION as well as possibly other installed equipment.

2.3.3 Cabling requirements To ensure a properly functioning ION, the following cabling requirements are highly recommended. Any variation will be at the sole responsibility of the dealer or installer. Detailed installation diagrams are provided in Section 3 of this manual.

Install each cable with an 8 inch [203 mm] service loop to allow for easy servicing of the ION unit.

2.3.3.1 Power (J1) Each ION is shipped with a circular LEMO 8-pin male connector, P/N FGN.1M.308.XLCT to be

Installation

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used as the power connector. If you wish to use a different power connector, the connection to 28VDC input on the ION and 28VDC GND are highly recommended to be a twisted pair. Use of 22 AWG wire size is recommended. J1 also contains provisions for GPIO1 and GPIO2 and aircraft panel dimmer brightness control.

Pin Function Description 1 28V Connect to 28V power source 2 28V GND Ground for 28V power source 3 Panel Brightness Panel brightness can be wired to aircraft cockpit dimmer

knob and has a maximum voltage input of 30V 4 Panel Brightness GND Ground for panel brightness 5 GPIO 1 GPIO 6 GPIO 1 GND GPIO Ground 7 GPIO 2 GPIO 8 GPIO 2 GND GPIO Ground

2.3.3.2 Ethernet (J2) Churchill Navigation recommends using either PicWire PIC E50824 or EMTEQ D100-0824-006 4-pair Ethernet cable. Both can be purchased from Churchill Navigation or directly from their respective manufacturers at http://www.picwire.com or http://www.emteq.com Use the connection labeled “J2 - Ethernet”. Twisted pair is indicated by color block.

Pin Function Wire color 1 TX-/BiD1- Orange 2 TX+/BiD1+ Orange/White 3 RX-/BiD2- Green 4 RX+/BiD2+ Green/White 5 BiD4- Brown 6 BiD4+ Brown/White 7 BiD3- Blue 8 BiD3+ Blue/White

2.3.3.3 Misc. (J3) – USB, Audio, ARINC J3 contains connection provisions for Audio in/out, ARINC and USB connectivity. Twisted pairs are indicated by color block and noted in the “pair with” column.

Pin Function Description Pair with 1 AUDIO OUT L Audio-out, left channel -- 2 AUDIO IN R HIGH Audio-in, right channel -- 3 AUDIO IN L HIGH Audio-in, left channel -- 4 USB 5V USB 5V -- 5 USB +* USB + -- 6 USB -* USB - -- 7 ARINC TX1-* ARINC transmit 1- ARINC TX1+ 8 ARINC RX2-* ARINC receive 2- ARINC RX2+ 9 ARINC RX2+* ARINC receive 2+ ARINC RX2-

10 ARINC RX1-* ARINC receive 1- ARINC RX1+

(Table continued next page)

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11 ARINC RX1+* ARINC receive 1+ ARINC RX1- 12 AUDIO OUT R Audio-out, right channel -- 13 AUDIO IN R LOW -- 14 AUDIO IN L LOW -- 15 USB GND Ground -- 16 ARINC ARINC Ground -- 17 ARINC TX1+* ARINC transmit 1+ ARINC TX1- 18 AUDIO OUT GND Audio Out Ground -- 19 GND Ground --

* Twisted pair required. For USB applications using J3, Churchill Navigation recommends the following:

Option A: Carlisle 28433/02171LX-4. This cable can be purchased directly from Carlisle: http://www.carlisleit.com Option B: EMTEQ U090-0422-100: This cable can be purchased directly from Emteq: http://www.emteq.com

USB performance cannot be guaranteed at cable lengths greater than 10ft (3.04m) without the use of an extender. Contact Churchill Navigation for additional information.

Aircraft Audio Setup Recommendations: For best audio quality, Churchill Navigation recommends that the ION audio input be connected to a balanced (chassis ground independent) output, with -15 dBV signal levels. It is also recommended to connect the ION audio input to a COM port, rather than a headset output. To connect an unbalanced audio signal, ensure that the ground signal from the audio source is shorted to ground at the source. This ground of the audio signal should then be connected to pins 13 and 14 of J3 on the Ion. The recommended ION audio setup has been tested on common aircraft audio control systems including the Eagle Copters USA (Geneva Aviation) G13000 Digital Audio Router and Technisonic A711 and A711X. If you have questions regarding the best audio setup for your installation, please contact Churchill Navigation.

ION can be configured to record stereo audio as two separate channels; ICS as channel 1 and RX/TX (Comm) as channel 2, for example. To do this, separate audio-in via J3 pin 2 and pin 3.

2.3.3.4 Serial Com (J4) – RS232, RS422 J4 contains connection provisions for RS232 and RS422 serial communications. Twisted pairs are indicated by color block and noted in the “pairing” column.

The maximum speed for cable runs of less than 25 feet [7.62m] is 256 kbit/s for

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RS232 and 8 Mbit/s for RS422.

Pin Function Description Pair with 1 RS232C TX RS232C transmit from ION -- 2 RS232C RX RS232C receive to ION -- 3 RS232A TX RS232A transmit from ION -- 4 RS232A CTS RS232A Clear to Send -- 5 RS232B TX RS232B transmit from ION -- 6 RS232B RX RS232B receive to ION -- 7 RS232B RTS RS232B Request to Send -- 8 RS422A RX-* RS422A receive to ION - RS422A RX+ 9 RS422A TX-* RS422A transmit from ION - RS422A TX+

10 RS422A TX+* RS422A transmit from ION + RS422A TX- 11 RS422B RX+* RS422B receive to ION + RS422B RX- 12 RS422B TX+* RS422B transmit from ION + RS422B TX- 13 RS232D TX RS232D transmit from ION -- 14 RS232D RX RS232D receive to ION -- 15 RS232E RX RS232E receive to ION -- 16 RS232E TX RS232E transmit from ION -- 17 GND RS232C Ground (RS232C TX/RX) -- 18 RS232A RX RS232A receive to ION -- 19 RS232A RTS RS232A Request to Send -- 20 GND RS232B Ground (RS232B TX/RX) -- 21 RS232B CTS RS232B Clear to Send -- 22 RS422A RX+* RS422A receive to ION + RS422A RX- 23 RS422B RX-* RS422B receive to ION - RS422B RX+ 24 RS422B TX-* RS422B transmit from ION - RS422B TX+ 25 GND RS232D Ground (RS232D TX/RX) -- 26 GND RS232E Ground (RS232E TX/RX) -- 27 GND Ground (Extra) -- 28 GND RS232A Ground (RS232A TX/RX) -- 29 GND RS422A Ground (RS422A TX/RX) -- 30 GND RS422B Ground (RS422B TX/RX) --

* Twisted pair required.

2.3.3.5 BNC (J5, J6, J7) – 75 Ω HD-SDI COAX Cable ION has two HD-SDI in connections and one HS-SDI video out connection. When used with gyro-stabilized gimbals, HD-SDI video 1 (J5) is typically used for Video In Command, HD-SDI video 2 (J6) is typically used for a hoist camera, etc. All BNC connectors use the center pin for the signal and the shell as the ground. In almost all applications, Churchill Navigation recommends use of PicWire PIC V73263 lightweight 75ohm coaxial cable, P/N 190712, available from Churchill Navigation or http://www.picwire.com If an installation requires alternative cabling, please use the following:

Installation

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Alternative A: RG59 can be used in place of PicWire PIC V73263. The proper connector is Amphenol Connex 112123. These are available from Churchill Navigation or http://www.digikey.com Alternative B: If RG179 is required by other equipment (ex. MX-10 gimbal), then for EMI purposes, DOUBLE high performance 360 degree EMC individual braid shielding must be done to RG179 cable from end to end. The proper connector is Amphenol Connex 112133, available from Churchill Navigation or http://www.digikey.com

2.3.3.6 BNC (J8, J9, J10) – Analog video ION is capable of recording from composite or component video sources. PAL, NTSC, S-Video, RS-170, and component-in are supported. The following configurations are allowed:

Composite Video In (CVBS)

S-Video In Component Video In (YUV)

Component Video In (RGB)

J8 J8-Luma (Y) J9-Chroma (C)

J8-Luma (Y) J9-Blue Chroma (Pb) J10-Red Chroma (Pr)

J8-Green (SYNC) J9-Blue J10-Red

For all BNC connectors, the center conductor pin is the signal and the shell is the ground.

Supported Analog Video Types ION supports input from the following analog video types:

− Composite − S-Video − Component_YUV_480i − Component_RBG_480i − Component_YUV_576i − Component_RBG_576i − Component_YUV_480p − Component_RBG_480p − Component_YUV_576p − Component_RBG_576p

2.3.3.7 All Other Cables Other cables can be selected at the installer’s discretion to meet the needs of the installation.

All cables MUST BE SHIELDED. This includes power cables.

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Section 3: Aircraft Post-Installation Testing Procedures 3.0 Description The following tests should be performed post-installation to confirm the correct operation of the ION video recorder in airborne applications. Additionally, these tests will identify any interference that the ION installation may cause with existing aircraft systems. If the installed system passes all of the applicable EMI tests, then no further action is required. If interference is observed, then the interference must be assessed against the appropriate standards of airworthiness for the system in question.

3.1 Methodology Most EMI tests can be conducted on the ground unless otherwise noted. Testing recommendations for various aircraft system tests are provided below. During all tests, it is recommended that users switch the ION unit on and off as often as required to evaluate potential EMI in all phases of ION operation.

ADF If possible set the ADF to a nearby navigation station and monitor for interference.

Autopilot If the aircraft is equipped with an autopilot or a stability augmentation system, test fly the aircraft and verify that operation of the ION does not have adverse effects on these systems.

GPS The GPS should be operational and navigating with at least the minimum compliment of satellites. Observe the GPS for any degradation in satellite status, loss of RAIM, or warning messages/flags.

Transponder The transponder and encoder should be monitored with ramp test equipment. Set the output of the transponder test set to 3db above the output necessary to achieve 90% reply.

VHF Comm Radio

The VHF comm radio should have the squelch open. Listen for any noise or detected audio signals on the VHF comm radio(s).

Navigation Radios

Operation of the Navigation radios (VOR/LOC/GS/DME receiver(s)) should be tested using known operational facilities. Listen for any noise or detected audio signals on the VOR/LOC/GS receiver audio; look for any moment of flags or needles on the VOR/LOC/GS navigation display(s).

Testing Procedures


3.2 Power-on Checks Prior to performing any other tests, the user should confirm the basic operation of the ION unit. This can be conducted using ground power or in-air using aircraft power.

1) Power the ION on and confirm the boot sequence. 2) With either USB or SD removable media inserted, use the outer knob to select a video channel

from which you want to record and press the REC button. Ensure no faults. 3) End recording by pressing the REC button a second time. 4) Playback recorded video using:

a. The ION unit’s on-screen playback capability, or b. The removable media by inserting it into a Windows PC or Macintosh computer and

playing back the recorded .TS file. Churchill Navigation recommends using the VLC Player available from videolan.org for playback if you encounter any difficulty playing files back with your normal media player.

If unable to successfully complete any of these steps, begin by rechecking wiring, connections, and if necessary, contact Churchill Navigation Support for further troubleshooting.

3.3 EMI Test List the power plant, fuel, and other electric instruments not already in the chart provided and note any anomalies that occur due to operation of the ION. Assess the results.

Aircraft communications & navigation equipment tests Pass/Fail Com 1&2 Transponder & Encoder ADF 1 & 2 Glideslope 1&2 VOR/LOC 1&2 DME 1&2 Compass Directional Gyro GPS Digital Clock

Autopilot tests Pass/Fail Autopilot

(Table continued next page)

Testing Procedures


Coupled Approach Stability Augmentation Systems

Aircraft engine systems tests Pass/Fail Fuel Pressure Oil Temperature Amps Bus Voltage Fuel % Ng TOT Torque % Annunciators Oil Pressure

Other systems tests (as identified by the user) Pass/Fail

Testing Procedures


Section 4: Installation Diagrams

The following pages contain the installation diagrams and specific notes for the ION that were current as of the printing of this manual. To obtain always up-to-date installation drawings, ICDs, and much more, visit: www.churchillnavigation.com/specifications

5.75

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SYSTEM WEIGHT: 2.6 lbs [1.22 kg] ±.05 lbs [0.02 kg]

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INSTALLATION NOTES:ION IS CASE GROUNDED THROUGH DZUS MOUNT. IF THE DZUS 1.MOUNT IS NOT DIRECTLY GROUNDED TO THE CHASIS, USE A MINIMUM OF 16-GAUGE WIRE TO GROUND THE DZUS MOUNT PRIOR TO ION OPERATION.EXPOSED ALUMINUM IS CHROMATED. DO NOT CHEMICALLY 2.COAT OR COVER WITH NON-CONDUCTIVE MATERIAL.ALL GROUND PINS EXCEPT 28V RETURN ARE GROUND 3.CONTINUOUS TO CASE.28V INPUT IS REVERSE-POLARITY PROTECTED.4.RECOMMENDED POWER WIRE SIZE: 22AWG.5.MAXIMUM POWER DRAW IS 112 WATTS (4A ON 28VDC).6.

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PROPRIETARY AND CONFIDENTIALTHE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFCHURCHILL NAVIGATION. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFCHURCHILL NAVIGATION IS PROHIBITED.

ALL DIM IN INCHES [MM]WEIGHT IN LBS [KG]

5/18/17*Includes all Ion versions

J8 J9 J10

J5 J6 J7

COMPOSITE VIDEO IN (CVBS): J8

S-VIDEO IN:J8-LUMA (Y)J9-CHROMA (C)

BNC CONNECTION:CENTER PIN: SIGNALSHELL: GROUND

HD-SDI VIDEO 1 IN:J5

HD-SDI VIDEO 2 IN:J6

HD-SDI VIDEO OUT:J7

COMPONENT VIDEO IN (YUV):J8-LUMA (Y)J9-BLUE CHROMA (Pb)J10-RED CHROMA (Pr)

COMPONENT VIDEO IN (RGB):J8-GREEN (SYNC)J9-BLUEJ10-RED

For use with gyro-stabilized gimbals, HD-SDI video 1 is typically used for Video In Command, HD-SDI video 2 is typically used for hoist camera

J1 J2

COMJ5:HD SDI 1 IN

ETHERNETPOWER

ANALOG INJ8,9,10

J7:HD SDI OUTJ6:HD SDI 2 IN J4J3 MISC.

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J1: Power/GPIO1.28V2.28V GND3.Panel Brightness4.PB GND5.GPIO 16.GPIO 1 GND7.GPIO 28.GPIO 2 GND

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J2: Ethernet1:TX-/BiD1- (Orange)2:TX+/BiD1+ (Orange/White)3:Rx-/BiD2- (Green)4:RX+/BiD2+ (Green/White)5:BiD4- (Brown)6:BiD4+ (Brown/White)7:BiD3+ (Blue)8:BiD3- (Blue/White)

J3:1:AUDIO OUT L2:AUDIO IN R HIGH3:AUDIO IN L HIGH4:USB 5V5:USB D+6:USB D-

7:ARINC TX1-* 8:ARINC RX2-* 9:ARINC RX2+*10:ARINC RX1-*11:ARINC RX1+*12:AUDIO OUT R

13:AUDIO IN R LOW14:AUDIO IN L LOW15:USB GND16:ARINC GND17:ARINC TX1+*18:AUDIO OUT GND19:GND

Panel Brightness is to be wired to aircraft cockpit dimmer knob and has a maximum voltage input of 30V

*AVAILABLE ONLY ON ION REV A

MISC.J3 J4J6:HD SDI 2 IN J7:HD SDI OUT

ANALOG INJ8,9,10

POWER ETHERNET

J5:HD SDI 1 IN COM

J2J1

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While populating LEMO connectors, please follow the pattern on the rear of the male LEMO, as seen to the left

Mating Connector(Specifically FGN.1M.308.XLCT)

Maximum current draw on rear USB is 1 Amp

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J4: SERIAL PORTS 1: RS232C TX 2: RS232C RX 3: RS232A TX 4: RS232A CTS 5: RS232B TX 6: RS232B RX 7: RS232B RTS 8: RS422A RX-* 9: RS422A TX-*10: RS422A TX+*

11: RS422B RX+*12: RS422B TX+*13: RS232D TX14: RS232D RX15: RS232E RX16: RS232E TX17: GND (RS232C)18: RS232A RX19: RS232A RTS20: GND (RS232B)

21: RS232B CTS22: RS422A RX+*23: RS422B RX-*24: RS422B TX-*25: GND (RS232D)26: GND (RS232E)27: GND28: GND (RS232A)29: GND (RS422A)30: GND (RS422B)

MAXIMUM SPEEDS FORCABLES LESS THAN 25FT RS232: 256kbpsRS422: 8Mbps

*TWISTED PAIR REQUIRED


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J1:

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MATING CONNECTOR PLUGS(CABLE TERMINATION)

FGU.1M.308.XLCT

FGN.1M.308.XLCT (One Provided with each Ion)

FMN.2M.319.XLCT

FMN.3M.330.XLCT

All Lemo Connectors Use: Crimp tool: DPC.91.701.V Pin Positioner: DCE.91.070.5MVC Pin Extractor: DCF.93.070.4LT

Churchill has stock of all necessary connectors and tools


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CABLING REQUIREMENTSIn order to ensure a properly working Churchill Navigation Ion System, these cabling requirements are highly recommended and any variations will be at the sole responsibility of the installer. Please also install each cable with an 8 inch service loop for easy removal and replacement of unit.

Power CableThe connection to 28V input on the Ion and 28V GND are highly recommended to be a twisted pair.

75ohm HD-SDI COAX CABLEOption APicWire PIC V73263 is highly recommended. A 74271142S Ferrite should be placed on the cable closest to the Ion to reduce noise further. The proper connector is PicWire P/N 190712. These are available from Churchill Navigation or at http://www.picwire.com/pdfs/PIC_Connectors/PIC_190712.pdf.

RG59 is also highly recommended. A 74271112S Ferrite should be placed on the cable closest to the Ion to reduce noise further.The proper connector is Amphenol Connex 112123. These are available from Churchill Navigation or at http://www.digikey.com/product-search/en/connectors-interconnects/coaxial-connectors-rf/1443098?k=112123

Option BIf RG179 is required by other equipment (ex. MX-10 gimbal), then for EMI purposes, DOUBLE high performance 360 degree EMC individual braid shielding must be done to RG179 cable from end to end. A 74271142S Ferrite should be placed on the cable closest to the Ion to reduce noise further. The proper connector is Amphenol Connex 112133. These are available from Churchill Navigation or at http://www.digikey.com/product-search/en?wt.z_cid=ref_hearst_0211_buynow&site=us&mpart=112133&v=115

CRIMPING TOOLYou will need the correct crimping tool for the connectors selected. A few examples are listed below and are available through Churchill Navigation:

Connector: Crimp Die: Picwire P/N 190712 M22520/5-41Amphenol 112123 .255/.213/.068Amphenol 112133 .178/.128/.068

All Lemo Connectors Crimp tool: DPC.91.701.V Pin Positioner: DCE.91.070.5MVC Pin Extractor: DCF.93.070.4LT

USB CABLEUSB performance cannot be guaranteed at cable lengths greater than 15ft without the use of an extender. Contact Churchill Navigation for further details.

Option ACarlisle 28433/02171LX-4 http://www.carlisleit.com/product/usb-cables. This cable can be purchased directly from Carlisle

Option BEMTEQ U090-0422-100: http://www.emteq.com/cmsdocuments/EMTEQ_U090-0422-100.pdf & http://www.emteq.com/entertainment.php This cable can be purchased directly from Emteq.

ETHERNET CABLEPicwire PIC E50824 is highly recommended. This can be purchased directly from PICwire at http://www.picwire.com/products/data_mates.php

EMTEQ D100-0824-006 is also highly recommended. This can be purchased directly at http://www.emteq.com/ethernet-and-databus-cables.php

ALL OTHER CABLES - MUST BE SHIELDEDAll other cable can be selected by installer and all cables must be shielded, including power cables.

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http://www.picwire.com/pdfs/pic_connectors/pic_190712.pdf. <font

AVAILABLE FROM CHURCHILL NAVIGATIONCONN-ION

ION Connector Kit (Includes all below)Churchill

Navigation P/N Manufacturer P/N Description

CONN-PR-308 FGN.1M.308.XLCT J1 Power/GPIO - Lemo w/ pins

CONN-ETH-308 FGU.1M.308.XLCT J2 Ethernet - Lemo w/ pinsCONN-SER-330 FMN.3M.330.XLCT J4 Serial - Lemo w/ pins

CONN-PIC PIC 190712 75Ω BNC plug - PICWire V73263CONN-RG59 Amphenol 112123 75Ω plug - RG59

CONN-RG179 Amphenol 112133 75Ω BNC plug - RG179CONN-SR-9N Amphenol M85049/38-11N Strain Relief ConnectorCONN-SR-11N Amphenol M85049/38-11N Strain Relief ConnectorCONN-SR-13N Amphenol M85049/38-13N Strain Relief ConnectorCONN-FER-S 74271142S Small Snap on FerriteCONN-FER-L 74271112S Large Snap on FerriteCONN-FER-K 74271 Ferrite Key

ToolsChurchill

Navigation P/N Manufacturer P/N Description

TOOL-PIC HX4 5120-01-335-8575 Hand crimp tool for PICWire BNC

TOOL-PIC-DIE M22520/5-41 Die set for PICWire 190712 BNC (.290/.178)

TOOL-RG59 .255/.213/.068 Die Crimp tool and die for 112123 BNC

TOOL-RG179 .178/.128/.068 Die Crimp tool and die for 112133 BNC

TOOL-LEMO DPC.91.701.V Hand crimp tool for LEMO

TOOL-LEMO-PTNR DCE.91.070.5MVC Pin Positioner for LEMO Crimp

TOOL-LEMO-EXTR DCF.93.070.4LT Pin Extractor for LEMO

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ionion is intended for dzus mount (or similar) installations. if you are unsure of the installation...

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