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Equipment Installation Manual, GDC40 Iridium Interface Unit
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EQUIPMENT INSTALLATION MANUAL
GDC40 IRIDIUM INTERFACE UNIT
P/N 1061-4000-XX-001( )
Rev A
DAC International 6702 McNeil Drive Austin, TX 78729
©Copyright 2006, DAC International. All rights reserved.
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RECORD OF REVISIONS
REV DESCRIPTION DATE APPROVED
IR INITIAL RELEASE, E468 3/10/06 LW A Added acceptable alternative for connector 1/28/09 BH
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Table of Contents RECORD OF REVISIONS ......................................................................................................................................... 2 INTRODUCTION: ...................................................................................................................................................... 4 DESCRIPTION: .......................................................................................................................................................... 4 PART NUMBERS:...................................................................................................................................................... 5 REGULATORY COMPLIANCE: .............................................................................................................................. 5
Software ................................................................................................................................................................... 5 Environmental.......................................................................................................................................................... 5
SUPPLIED EQUIPMENT........................................................................................................................................... 6 SPECIFICATIONS:..................................................................................................................................................... 7
Physical:................................................................................................................................................................... 7 Electrical: ................................................................................................................................................................. 7 Serial Data Input and Output: .................................................................................................................................. 7 Iridium Interface Unit Output .................................................................................................................................. 9 Weight On Wheels Input: ........................................................................................................................................ 9 Panic Button Input: .................................................................................................................................................. 9 Disconnect Button Input: ......................................................................................................................................... 9 Certification: ............................................................................................................................................................ 9 Reliability:................................................................................................................................................................ 9
OPERATION:............................................................................................................................................................ 10 Overview................................................................................................................................................................ 10
INSTALLATION ...................................................................................................................................................... 11 Material Not Supplied............................................................................................................................................ 11 Special Tools.......................................................................................................................................................... 11 Mounting Considerations....................................................................................................................................... 12 Wiring Considerations ........................................................................................................................................... 12
Baud Rate Selection........................................................................................................................................... 12 GPS Receiver Setup........................................................................................................................................... 12
REMOVAL AND REPLACEMENT........................................................................................................................ 13 Removal, GDC40................................................................................................................................................... 13 Replacement, GDC40 ............................................................................................................................................ 13
EQUIPMENT CHECKOUT...................................................................................................................................... 14 Ground Functional Test ......................................................................................................................................... 14
CONTINUED AIRWORTHINESS: ......................................................................................................................... 15 ENVIRONMENTAL:................................................................................................................................................ 16 CONNECTOR PIN OUT: ......................................................................................................................................... 17 OUTLINE DRAWINGS............................................................................................................................................ 18
GDC40 Outline ...................................................................................................................................................... 18 SLIDE LATCH ASSEMBLY.................................................................................................................................... 19 APPENDIX A – DATA FORMATS......................................................................................................................... 20 APPENDIX B - TYPICAL INTERCONNECT ........................................................................................................ 21
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INTRODUCTION:
This manual contains installation data, specifications and Instructions for Continued Airworthiness for the DAC International Model GDC40 Iridium Interface Unit, Part Number 1061-4000-XX-001( ).
DESCRIPTION:
The GDC40 Iridium Interface Unit (IIU) with software version 001( ) is an aircraft accessory designed to receive RS232 serial data from one of four possible positioning systems shown in Figure 1. From that data, it will produce, depending upon initial installation configuration straps, one of four converted data streams according to conversion table shown in Table 1 Serial Data Formats. The GDC40 output signal connects to an existing Iridium ST-3100 satellite phone. The GDC40 does not reduce or otherwise alter any existing safety features of the aircraft. The GDC40 provides geospatial data only.
AMS-3000S
GPS-2003ZZCompatible
NMEA 0183Compatible
FF2101 SeriesCompatible
COMChannel
w/ eitherSBDOR
MobileTerminated
Mode Enabled
PanicButton
DisconnectSwitch
OperationalLED
Binary State Inputs
GDC 40Iridium
Interface Box
19200bpsRS-232C
interface toIridiumPhone
DataConversion
OR
1 of 4 possibledata input formats
configured atinstallation
OR
OR
EXTERNAL
DATA
BUS
9600bpsRS-232Cinterface
A0 PacketData Format
4800bpsRS-232Cinterface
9600bpsRS-232CinterfaceAviation
Data Format
9600bpsRS-232Cinterface
75 PacketData Format
StrapsWeight- on -
Wheels
Figure 1 Interface Block Diagram
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PART NUMBERS:
The GDC40 Iridium Interface Unit is available under the following part numbers:
1061-4000-01-001( ) GDC40 Iridium Interface Unit
REGULATORY COMPLIANCE:
Software
The Model GDC40 software was developed in accordance with RTCA/DO-178B to criticality level E.
Environmental
The Model GDC40 meets the DO-160E environmental categories listed later in this manual.
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SUPPLIED EQUIPMENT
Each Iridium Interface Unit is shipped with the following items: Part Number Description Qty
1061-4000-01-001( ) GDC40 Iridium Interface Unit 1 1061-4200-01 Installation Kit, GDC40 Iridium Interface Unit 1 Complete installation kits are available under kit part number 1061-4200-01. Individual pieces are available under the part numbers shown. Contact DAC International sales to place orders. Part Number Description Qty
1061-4200-01 Installation Kit, GDC40 Iridium Interface Unit M24308/2-3F Connector, Receptacle, 25 pin D-Sub 1 M24308/2-3* Connector, Receptacle, 25 pin D-Sub - P10220 Backshell, 25-Pin D-Sub 1 1061-2510-01 Equipment Installation Manual for the GDC40 1 M39029/63-368 Socket, Crimp Style, female 25 P10219 Slide Latch Kit, shell size 3 1
* - This part is an acceptable alternative to M24308/2-3F and either part may be used in the installation of the Iridium Interface Unit. In the event that this part is used, it shall be used in the quantity listed for M24308/2-3F.
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SPECIFICATIONS:
Physical:
The GDC40 attaches to the airframe via four mounting holes. See the paragraph titled Outline Drawing for further details.
IIU LRU
Height ................................................1.25”
Width .................................................5.22” (Includes mounting flange)
Depth..................................................3.54”
Weight................................................0.4 lb.
Electrical:
Input Voltage .....................................14 / 28 VDC (10Vdc – 32Vdc operational)
Input Current......................................0.1 Amp maximum at 28 VDC
Serial Data Input and Output:
Format................................................RS-232 serial data shall be in one of five formats; NMEA, A0, C0, 75, or Aviation Data format.
RS-232 serial output data shall be in one of three formats; A0, C0, or 51.
Baud Rate...........................................Device dependant (4800, 9600, 19200) Note 1:
Note 1: ...............................................Baud Rate of both Iridium RS-232 and 1-of-4 data source RS-232 is configured at installation via straps on P1 in accordance with Table 1.
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SERIAL DATA FORMATS:
INPUT Serial Data Format OUTPUT Serial Data Format
AMS-3000S Iridium PhoneA0 packet only
FF2101 AMS-3000SAviation Data A0 packet only
NMEA Device GPS-2003ZZGGA / VTG / RMC 75 packet only
Sentences
GPS-2003ZZ75 packet only
Iridium PhoneC0 packet only
9600 BPS, 8 Data, 1 Stop, No parity
9600 BPS, 8 Data, 1 Stop, No parity
GD
C 40 Physical Interface
19,200 bps, 8 data, 1 stop bit and no PARITYA0, C0 or 51 packet
Only
19,200 bps, 8 data, 1 stop bit and no PARITY
4800bps, 8 data, 1 stop, No parity
9600 bps, 8 data, 1 stop, No parity
9600 bps, 8 data, 1 stop, No parity
9600 bps, 8 data, 1 stop, No parity
Table 1 Serial Data Formats
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Iridium Interface Unit Output
Description.........................................RS-232 configured with 8 data bits, 1 stop bit and no parity. 19,200 bps communication with the Iridium phone, 9600 bps to the Airmap system, 9600 bps to the FF2101 compatible system, 4800 bps to the NMEA compatible system and 9600 bps to the GPS2003 compatible system.
Weight On Wheels Input:
Description.........................................Discrete inputs to the GDC40 at J1-09 and J1-13 supplied from a weight-on-wheels switch.
Normal: (J1-13 Open)........................Open = In Air Ground = On Ground
Reverse: (J1-13 Ground)....................Ground = In Air Open = On Ground
Panic Button Input:
Description.........................................Discrete input to the GDC40 at J1-22 supplied from a N.O. SPST switch.
Voltage:..............................................Normally open being Hi-Z, Closed (switch pushed) being 0V.
Disconnect Button Input:
Description.........................................Discrete input to the GDC40 at J1-10, supplied from a N.O. SPST switch.
Voltage:..............................................Normally open being Hi-Z, Closed (switch pushed) being 0V.
Certification:
DO-178B............................................Level E
DO-160E............................................B1/CACUXXXXXXZBABATM/XXE1X/XXA
Reliability:
MTBF ................................................Greater than 50,000 hours.
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OPERATION:
Overview
The GDC40 Iridium Interface Unit receives RS232 serial data in NMEA, A0, C0, 75 or Aviation formatted navigation data from any one of four devices and enables communication of that data to an Iridium Satellite phone. The IIU extracts information from the data stream of the GPS/Airmap system and converts the format of the data into the selected format according to instructions received from the configuration packet previously received by the Iridium Satellite phone during initialization of the system.
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INSTALLATION
This section provides details for the installation of the GDC40 Iridium Interface Unit, including configuration, wiring, mounting and checkout procedures. Follow the procedures and recommendations found in this section to assure a successful installation. Read this entire section before beginning the installation. Complete an electrical load analysis in accordance with AC 43.13-1B, Chapter 11 prior to starting the aircraft modification to insure the aircraft has sufficient load capability. Complete an aircraft weight and balance prior to aircraft modification to insure the aircraft has sufficient weight and CG margin.
Material Not Supplied
The following items are required for the installation but not supplied: • Wire: MIL-W-22759/16 or equivalent • Shielded Wire: MIL-C-27500 or equivalent • Mounting screws: MS35206 6-32, 4 each • Circuit Breaker: Klixon 7277-2-2 or equivalent • Tie straps or lacing cord • Ring terminals (for grounding) • Splices
Special Tools
Use the following crimp tool to ensure reliable crimp contact connections to connector J1. • Crimp tool M22520/2-01 • Positioner M22520/2-08
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Mounting Considerations
The GDC40 Iridium Interface Unit can mount in the avionics bay, shelf or other suitable structure. It can be mounted in any orientation.
Wiring Considerations
Wiring should be done in accordance with AC 43.13-1B, Chapter 11. Refer to the typical interconnect diagram later in this manual for specifics. Use 22 to 24 AWG wire for all connections. Fabricate wiring harness; refer to the interconnect diagrams and pin description. Test all the wiring for continuity and for shorts. Insure aircraft power is on the correct pins of J1; refer to Table 6. Install slide latch assembly onto J1 using instructions found later in this manual. Baud Rate Selection
The GDC40 will accept three (3) baud rates for data configured by grounding pins P1-06 and P1-19 during cable assembly.
Equipment Baud Rate*
J1-06 J1-19
AMS-3000S 9600 Ground Ground FF2101
compatible 9600 Ground Open
NMEA compatible 4800 Open Ground
GPS-2003 compatible 9600 Open Open
Table 2 Baud Rate Selection *Note: Data transmission to Iridium phone is at 19200 bps regardless of data source rate selection GPS Receiver Setup
Refer to the manufacturer's instructions for the GPS interfaced to the GDC40 IIU. Configure the GPS to output the Aviation Format data described in Appendix A.
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REMOVAL AND REPLACEMENT
Removal, GDC40
1. Open the circuit breaker powering the GDC40.
2. Remove the connector by disengaging the slide latch then pulling the connector free.
3. Remove four (4) screws securing the unit to the airframe.
Replacement, GDC40
1. Open the circuit breaker powering the GDC40.
2. Attach the unit to the airframe with four (4) screws.
3. Seat the connector then engage the slide latch to secure.
4. Close circuit breaker.
5. Perform ground functional test found under Equipment Checkout in this manual.
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EQUIPMENT CHECKOUT
There are no operator controls associated with the GDC40 unit. The GPS receiver, Iridium phone and the Airmap system, if installed, must all be operational in order to perform this functional checkout.
Ground Functional Test
1. Perform GPS Receiver and Iridium phone installation and functional test. 2. Power up GPS receiver, Iridium phone and GDC40. 3. Using ground station, provide interrogation of Iridium phone system and validate correct response received
at ground station. 4. Remove phone from cradle – annunciator lamp should illuminate steady, replace the phone in cradle –
annunciator lamp should extinguish. 5. Depress panic button – annunciator lamp should blink, release panic button – annunciator lamp should
extinguish.
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CONTINUED AIRWORTHINESS:
This section provides data intended to assist the installer with establishing instructions for Continued Airworthiness as required by FARs 23.1529, 25.1529, 27.1529 and 29.1529. 1. Maintenance Manual information for the GDC40, which includes system description, removal instructions,
installation instructions and functional testing instructions, is contained in DAC International Installation Manual, 1061-2510-01 (this document).
2. Line Replaceable Unit (LRU) part numbers and other parts contained in the installation data package should
be placed in the aircraft operator’s appropriate airplane Illustrated Parts Catalog (IPC). 3. Wiring diagram information contained in the installation data package should be placed in the aircraft
operator’s appropriate airplane Wiring Diagram Manual. 4. Scheduled Maintenance Program tasks are as follows:
a. Recommended Periodic Scheduled Servicing: ............................None required b. Recommended Periodic Scheduled Preventive Maintenance Tests .......................................................................None Required c. Recommended Periodic Inspections:...........................................None Required d. Recommended Periodic Overhaul Period....................................None Required e. Special Inspection Requirements.................................................None Required
5. Application of Protective Treatments.....................................................None Required 6. Special Tools ..........................................................................................None Required 7. Electrical Loads for this appliance are as specified in the DAC International Installation Manual, 1061-2510-
01 (this manual). 8. There are no Airworthiness limitations associated with the installation of this appliance.
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ENVIRONMENTAL:
The GDC40 meets the environmental test categories detailed below in accordance with RTCA/DO-160D, Environmental Conditions and Test Procedures for Airborne Equipment. NOMENCLATURE: Model GDC40 Iridium Interface Unit PART NO: 1061-4000-XX-XXXX MANUFACTURER: DAC International ADDRESS: 6702 McNeil Drive, Austin, TX 78729
Section Category Remarks 4.0 Temperature and Altitude B1 Non-press, non-temperature
controlled, altitude 25,000 ft 5.0 Temperature Variation C 2°C degrees per minute 6.0 Humidity A Standard Humidity 7.0 Operational Shock and Crash Safety C Helicopters
8.0 Vibration U Helicopter, Unknown Frequencies
9.0 Explosion Proofness X Not Tested 10.0 Waterproofness X Not Tested 11.0 Fluids Susceptibility X Not Tested 12.0 Sand and Dust X Not Tested 13.0 Fungus Resistance X Not Tested 14.0 Salt Spray X Not Tested 15.0 Magnetic Effect Z Less than 0.3 meter 16.0 Power Input B DC equipment driven by
ALTs/RECTs with battery on bus 17.0 Voltage Spike B 56 volts 18.0 AF Conducted Susceptibility – Power Inputs
B Alternator / Rectifiers 19.0 Induced Signal Susceptibility A 20.0 Radio Frequency Susceptibility (Radiated and Conducted)
T 5 volts/meter 21.0 Emission of Radio Frequency Energy M Cockpit or passenger area 22.0 Lightning Induced Transient Susceptibility
XXE1X Waveform E, Level 1
23.0 Lightning Direct Effects X Not Tested 24.0 Icing X Not Tested 25.0 ESD A
Table 3 Environmental Requirements
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CONNECTOR PIN OUT:
The GDC40 contains a single 25-pin male connector, J1, per MIL-C-24308. The mating connector, P1, is described previously under the section “Equipment Supplied”.
Pin Signal Function 1 A+ 28 Vdc Primary Power (Input) 2 ACRFTTX Aircraft Equipment RS232 Transmit (Non-Iridium) (Out) 3 ACRFTRX Aircraft Equipment RS232 Receive (Non-Iridium) (In) 4 GND RS232 Common 5 BusyLight1 Iridium Busy Light Relay Output 6 HiBitDevSel Input Device Configuration Pin (Do Not Apply Voltage) 7 IridTX Iridium Transmit RS232 (Out) 8 IridRX Iridium Receive RS232 (In) 9 WonWheel Weight on Wheel Sensor Input (In)
10 DISCON Iridium Disconnect Switch Input (Do Not Apply Voltage) 11 Reserve Spare Discrete 12 13 /WeightOnWheels WonWheel Logic Selection (N.O./N.C. switch) 14 Power Common 28 Vdc Return 15 GND Chassis Ground 16 Serial Common RS232 Common 17 RESERVED (/PGM Enable)18 BusyLight2 Iridium Busy Light Relay Input 19 LoBitDevSel Input Device Configuration Pin (Do Not Apply Voltage) 20 RTS Iridium RTS Signal (Out) 21 CTS Iridium CTS Signal (In) 22 PANIC Operator Panic Input (Do Not Apply Voltage) (In) 23 ST_Ring_Indicator Iridium Ring Indicator (In) 24 25
Table 4 J1 Pin Description
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OUTLINE DRAWINGS
GDC40 Outline
Figure 2 GDC 40 Enclosure Dimensions Note: Dimensions are in inches.
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SLIDE LATCH ASSEMBLY
Assemble the slide latch mechanism, part number P10219, onto the mating connector as pictured using the hardware supplied with the slide latch.
SLIDE LATCH
SCREW
CONNECTOR
FLAT WASHER
NUT
LOCK WASHER
Figure 3 Slide Latch Assembly
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APPENDIX A – DATA FORMATS
The following table contains the minimum data set required by the GDC40. The GDC40 is designed to disregard additional data records transmitted to it. Insure the GDC40 is configured for the correct baud rate (refer to "Serial Baud Rate Selection" located earlier in this manual)
Data Packet Formats Description
A0 AMS-3000S Airmap system Aviation FF2101 Compatible system 51 or 75 GPS-2003 Compatible system NMEA GGA & VTG or RMC
NMEA Compatible system
Table 5 Data Packet Formats
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APPENDIX B - TYPICAL INTERCONNECT
The following section contains typical interconnect diagrams to aid in wiring the GDC40.
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SUPPLYPOWER
NOTE: PINS 6, 19, AND 13 ARE CONFIGURED AT INSTALLATION.
COMMONCHASSIS
+28VDC
AIRCRAFT TRANSMITAIRCRAFT RECEIVE
PANIC BUTTONDISCONNECT BUTTON
WEIGHT-ON-WHEELS INPUT
BUSY LIGHT INBUSY LIGHT OUT
IRIDIUM TRANSMITIRIDIUM RECEIVE
RTSCTS
/WEIGHT-ON-WHEELS SELECTLO BIT DEVICE SELECTHI BIT DEVICE SELECT
GDC40
INTERFACEBUSY LIGHT
IRIDIUM ST3100/
INTERFACEEMERGENCYHARDWARE/
MAPPINGGPS/
13196
212087
185
9102232
15141
0.5A
+28VDC BUS
Figure 4 Interface Connection Drawing
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8IRIDRX
LOBITDEVSELHIBITDEVSEL
WEIGHTonWHEELS
19
13
6
GND 421CTS
RTS 20
IRDITX
BUSYLIGHT2BUSYLIGHT1
7
185
WonWHEELS
DISCON
PANIC
10
9
22
15GND
SER COMACRFTRXACRFTTX
316
2
PWR COM 14A+ 1
NOT ON GROUNDON GROUND
OPENWEIGHTonWHEELS
WEIGHT-ON-WHEEL RELAY
DISCONNECT SW
PANIC SW
ON GROUNDNOT ON GROUND
WonWHEELSGND
MODEM GND
ST3100
LEDBUSY LIGHT
0.5A FUSE
GNDAUX-TX
AUX 6AMS-3000S
A+
A+
AUX-RXAUX 9AUX 5
c
GDC40
GNDOPEN
NaXS
RS232 TXRS232 RX
RS232 RTSRS232 CTS
Figure 5 GDC40 and AMS-3000S Interface Drawing
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8IRIDRX
LOBITDEVSELHIBITDEVSEL
WEIGHTonWHEELS
19
13
6
GND 421CTS
RTS 20
IRDITX
BUSYLIGHT2BUSYLIGHT1
7
185
WonWHEELS
DISCON
PANIC
10
9
22
15GND
SER COMACRFTRXACRFTTX
316
2
PWR COM 14A+ 1
NOT ON GROUNDON GROUND
OPENWEIGHTonWHEELS
NC
WEIGHT-ON-WHEEL RELAY
DISCONNECT SW
PANIC SW
ON GROUNDNOT ON GROUND
WonWHEELSGND
c
ST3100
LEDBUSY LIGHT
0.5A FUSE
A+
COM
FF2101
NONE
A+
10
J1
TX1
MODEM GND
GDC40
GNDOPEN
NaXS
RS232 TXRS232 RXRS232 RTSRS232 CTS
Figure 6 GDC40 and FF2101 Interface Drawing
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8IRIDRX
LOBITDEVSELHIBITDEVSEL
WEIGHTonWHEELS
19
13
6
GND 421CTS
RTS 20
IRDITX
BUSYLIGHT2BUSYLIGHT1
7
185
WonWHEELS
DISCON
PANIC
10
9
22
15GND
SER COMACRFTRXACRFTTX
316
2
PWR COM 14A+ 1
NOT ON GROUNDON GROUND
OPENWEIGHTonWHEELSNC (OPEN)
WEIGHT-ON-WHEEL RELAY
DISCONNECT SW
PANIC SW
ON GROUNDNOT ON GROUND
WonWHEELSGND
MODEM GND
ST3100
LEDBUSY LIGHT
SER COM
0.5A FUSE
-
A+
NMEA TXD
A+
c
GDC40
GPS NMEA OUTPUT
NaXS
GNDOPEN
RS232 TXRS232 RXRS232 RTSRS232 CTS
Figure 7 GDC40 and GPS NMEA OUTPUT Interface Drawing
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8IRIDRX
LOBITDEVSELHIBITDEVSEL
WEIGHTonWHEELS
19
13
6
GND 421CTS
RTS 20
IRDITX
BUSYLIGHT2BUSYLIGHT1
7
185
WonWHEELS
DISCON
PANIC
10
9
22
15GND
SER COMACRFTRXACRFTTX
316
2
PWR COM 14A+ 1
NOT ON GROUNDON GROUND
OPENWEIGHTonWHEELS
WEIGHT-ON-WHEEL RELAY
DISCONNECT SW
PANIC SW
ON GROUNDNOT ON GROUND
WonWHEELSGND
MODEM GND
ST3100
LEDBUSY LIGHT
0.5A FUSE
GPS-2003ZZ
A+
2
53
A+
RXDTXDCOM
c
GDC40
NC (OPEN)NC (OPEN)
NaXS
RS232 TXRS232 RXRS232 RTSRS232 CTS
GNDOPEN
Figure 8 GDC40 and GPS-2003ZZ Interface Drawing