veta high-power transmitter (vhpt) operations manual · 2012-11-12 · version date main changes...

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100-M0155X1A 1 of 27 Cobham Tactical Communications and Surveillance 1916 Palomar Oaks Way, Suite 100, Carlsbad, CA 92008 Tel: 760-496-0055 FAX: 760-496-0057 GMS Inc. doing business as Cobham Tactical Communications and Surveillance www.cobham.com/tcs The most important thing we build is trust. Technical Manual VETA High-Power Transmitter (VHPT) OPERATIONS MANUAL Includes VEPA or Standard Power Amplifier

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Page 1: VETA High-Power Transmitter (VHPT) OPERATIONS MANUAL · 2012-11-12 · Version Date Main Changes from Previous version Created by X1 08-14-2010 Initial Release R. Manvelyan X1A 06-08-2012

100-M0155X1A 1 of 27

Cobham Tactical Communications and Surveillance 1916 Palomar Oaks Way, Suite 100, Carlsbad, CA 92008 Tel: 760-496-0055 FAX: 760-496-0057

GMS Inc. doing business as Cobham Tactical Communications and Surveillance www.cobham.com/tcs

The most important thing we build is trust.

Technical Manual

VETA High-Power Transmitter (VHPT)

OPERATIONS MANUAL

Includes VEPA or Standard Power Amplifier

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GMS Inc. doing business as Cobham Tactical Communications and Surveillance www.cobham.com/tcs

Table of Contents

1. Important Warning and General Safety Information ..................................................................................... 5

2. Acronyms ......................................................................................................................................................................................... 7

3. Introduction .................................................................................................................................................................................. 8

3.1 About the Manual .................................................................................................................................................................. 8 3.2 Warranty .................................................................................................................................................................................... 8 3.3 Safe Operating Procedures ................................................................................................................................................. 8

4. General System Information ............................................................................................................................................. 9

4.1 Theory of Operation ............................................................................................................................................................. 9 4.2 Power Amplifiers (Standard or VEPA) ........................................................................................................................... 9 4.3 Applications .............................................................................................................................................................................. 9 4.4 Key System Features .......................................................................................................................................................... 10

5. Initial Check Out ..................................................................................................................................................................... 11

5.1 Getting Started ..................................................................................................................................................................... 11

6. Hardware Overview ................................................................................................................................................................ 13

6.1 VHPT Connectors ................................................................................................................................................................ 13 6.1.1 DC IN (J8) ....................................................................................................................................................................... 13 6.1.2 RF OUT (J1) .................................................................................................................................................................... 13 6.1.3 DATA/CONTROL (J6) ................................................................................................................................................. 14 6.1.4 AUDIO (J7) ................................................................................................................................................................... 14 6.1.5 Y/CVBS (J2) .................................................................................................................................................................... 15 6.1.6 SDI (Optional) (J3) ...................................................................................................................................................... 15

7. Software Overview ................................................................................................................................................................. 16

7.1 System requirements ......................................................................................................................................................... 16 7.2 Installation .............................................................................................................................................................................. 18

8. Specifications ............................................................................................................................................................................ 19

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List of Figures

Figure 1 – Basic HP-VDL Setup ........................................................................................................................................................ 11 Figure 2 – VHPT Front View ............................................................................................................................................................. 13 Figure 3 – PC Control Connections ............................................................................................................................................... 17

List of Tables

Table 1 ....................................................................................................................................................................................................... 13 Table 2 ....................................................................................................................................................................................................... 14 Table 3 ....................................................................................................................................................................................................... 15

List of Appendixes

Appendix A– References.................................................................................................................................................................... 21 Appendix B – Cable, Power (100-C0219*) ................................................................................................................................ 22 Appendix C – Cable, Audio (100-C0516*) ................................................................................................................................. 23 Appendix D – Cable, Data/Control (100-C0518*) .................................................................................................................. 24 Appendix E – Cable VHPT, FCON Control (100-C0549*) .................................................................................................... 25 Appendix F – Cable, Actuator,Cbox,RCU, Interface (100-C0257*) ................................................................................ 26 Appendix G – Cable, RCU2000, DB9 (FM-M) & PWR (100-C0129*) .............................................................................. 27

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Revision History

Version Date Main Changes from Previous version Created by

X1 08-14-2010 Initial Release R. Manvelyan

X1A 06-08-2012 Add pin outs (I/O connections) for PTO connectors. High power box now includes the use of the VEPA or the standard power amplifier. Differences between connections for each are noted in the manual. Add additional cable drawings for remote control units (RCU and FCON). Add figure showing physical connections between PC COM port and VHPT for PC control. Update pictures with latest front panels.

T. Giotta

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1. Important Warning and General Safety Information

The following information is presented to the operator to ensure awareness of potential harmful RF (radio frequency) exposure and general hazards. With regards to potential harmful RF electromagnetic fields the text below is only a brief summary highlighting the possible risks and how to minimize exposure. The summary is based on OET Bulletin 65 “Evaluating Compliance with FCC Guidelines for Human Exposure to Radiofrequency Electromagnetic Fields” (1). The user should carefully read and comprehend the following before operating the equipment and for additional in depth information refer to OET Bulletin 65.

1. FCC has set guidelines (1) for evaluating exposure to RF emissions that the user must be aware of when operating the microwave transmitter. The maximum power density allowed at 1500-100,000 MHz is 5mW/cm2 for occupational/controlled exposure* and 1mW/cm2 for general population/uncontrolled exposure**. These are the limits for maximum permissible exposure (MPE) as called out in the FCC guidelines (for the above mentioned frequencies).

2. Exposure is based upon the average time spent within the RF field with a given intensity (field units in mW/cm2). Hence it may be controlled (or at least minimized) by observing the safe distances and time exposed. Safe distances are calculated from equations predicting RF Fields (3).

3. The transmitter is capable of harmful radiation if safe operating practices are not observed. 4. Antenna minimum safe operating distance is 20cm (8 inches). It is the responsibility of the

qualified end-user of this intentional radiator to control the safe distances and exposure limits to bystanders. *”Occupational/controlled exposure limits apply to situations in which persons are exposed as a consequence of their employment and in which those persons who are exposed have been made fully aware of the potential for exposure and can exercise control over their exposure. Occupational/controlled exposure limits also apply where exposure is of a transient nature as a result of incidental passage through a location where exposure levels may be above general population/uncontrolled limits (see below), as long as the exposed person has been made fully aware of the potential for exposure and can exercise control over his or her exposure by leaving the area or by some other appropriate means……..” (2)

** “General population/uncontrolled exposure limits apply to situations in which the general public may be exposed or in which persons who are exposed as a consequence of their employment may not be made fully aware of the potential for exposure or cannot exercise control over their exposure. Therefore, members of the general public would always be considered under this category when exposure is not employment-related, for example, in the case of a telecommunications tower that exposes persons in a nearby residential area.“ (2)

(1) OET Bulletin 65, Apendix A Table 1 Limits for MPE http://www.fcc.gov/Bureaus/Engineering_Technology/Documents/bulletins/oet65/oet65.pdf

(2) OET Bulletin 65, page 9, definitions of types of exposure http://www.fcc.gov/Bureaus/Engineering_Technology/Documents/bulletins/oet65/oet65.pdf

(3) OET Bulletin 65, page 19, Equations for predicting RF Fields http://www.fcc.gov/Bureaus/Engineering_Technology/Documents/bulletins/oet65/oet65.pdf

5. Do not substitute any antenna for the one supplied or recommended by the manufacturer. The installer is responsible for ensuring that the proper antenna is installed.

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6. In should be noted that this device is an intentional radiator, hence: Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. NOTE: The manufacturer is not responsible for any radio or TV interference caused by unauthorized modification to this equipment. Such modifications could void the user’s authority to operate the equipment.

7. DC power to the unit should never be applied until the antenna (or other suitable load) has been attached to the RF output connector. Safe operating procedures must be observed when unit is transmitting into an antenna (see sections 1 & 2 above).

8. Electro-Static Discharge (ESD) precautions should be observed as a safe practice. 9. The transmitter will generate considerable heat and is the responsibility of the end user to properly

heat sink the device before using.

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2. Acronyms This section lists and describes the various acronyms used in this document.

Name Meaning 16QAM 16-state Quadrature Amplitude Modulation 64 QAM 64-state Quadrature Amplitude Modulation A/V Audio/Video AES Advanced Encryption System ABS Basic Encryption System (8 bit) ASI Asynchronous Serial Interface COFDM Coded Orthogonal Frequency Division Multiplexing CVBS Composite Video BDC Block-Down Converter FEC Forward Error Correction GUI Graphical User Interface I/O Input/ Output KBaud Kilobaud per second Kbps Kilobits per second M2D Messenger Decoder M2T Messenger 2 Transmitter Mbps Megabits per second MDL Messenger Digital Link MDR Messenger Digital Receiver MDT Messenger Digital Transmitter MER Modulation Error Rate MPEG Moving Picture Experts Group MVRD Messenger VETA Receiver Decoder NTSC National Television System Committee PAL Phase Alternation Line QPSK Quadrature Phase Shift Keying QAM Quadrature Amplitude Modulation RF Radio Frequency RX Receiver S/N Signal-to-Noise Ratio THD Total Harmonic Distortion TX Transmitter VDC Volts (Direct Current) VDL VETA Digital Link VEPA Very Efficient Power Amplifier

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3. Introduction

3.1 About the Manual GMS User Manuals focus on providing the end user an easy to understand operational instructions to quickly setup and deploy the equipment. The GMS Technical Operation Manuals focus on the technical details and setup of the equipment. The Technical Manuals also provide a more in depth explanation of the settings and specifications of the equipment that technicians can use to verify the operational status. 3.2 Warranty GMS offers a 12 month standard product warranty. During this period, should the customer encounter a fault with the equipment we recommend the following course of action:

• Check the support section of the website for information on that product and any software/firmware upgrades.

• If fault persists call our support line and report the fault. If fault persists and you are informed to return the product, please obtain an RMA number from the GMS support department or website and ship the equipment with the RMA number displayed and a description of the fault. Please email the support section the airway bill/consignment number for tracking purposes.

Depending on the nature of the fault GMS endeavor to repair the equipment and return it to the customer within 14 days of the item arriving at our workshops. Obviously it is impossible to cater for all types of faults and to manage 100% replacement part availability, and delays are sometimes inevitable. Please contact GMS for details of packages that can be tailored to meet your individual needs, whether they are service availability, technical training, local geographic support or dedicated spares holdings. 3.3 Safe Operating Procedures

• Ensure that the power supply arrangements are adequate to meet the requirements of VETA product.

• Operate within the environmental limits specified for the product. • Only authorized, trained personnel should open the product. There are no functions that

required the User to gain access to the interior of the product.

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4. General System Information 4.1 Theory of Operation One of the biggest problems encountered in the transition from an analog to a digital A/V Platform has been the inherent digital coding delays that in some digital systems are 400ms or more. The VHPT/VR combination employs a specially designed ‘low delay’ coding technology, which provides an end-to-end latency of approximately 198ms without the introduction of any further MPEG encoding artifacts. This ensures that the picture you see is what is happening now - crucial for applications such as sports coverage, surveillance, and law enforcement, where personnel are reacting to real-time events The VHPT accepts a composite or S-Video Input, Analog Stereo Audio Inputs (with MIC Bias) and a RS232 User Data Input. There is also an option to accept SDI Video. The Video is compressed according to MPEG-2 or MPEG-4 Part-2 (Optional) specifications. The Audio is sampled and compressed. The Audio, Video and Data packet streams are multiplexed with basic service data to indicate the service name. The stream can be scrambled with a simple fixed key scrambling system (ABS standard) to give basic protection in sensitive applications. Additional security is accomplished with the optional AES scrambling system. The transport stream is sent for FEC preprocessing and COFDM modulation. The modulated signal is amplified and output through an N-F connector. The VHPT control Scheme uses a Configuration Group or Set of Presets that completely define the operating mode of the VHPT. This includes 99% of the controllable parameters in the transmitter including frequency, RF power level, all modulation parameters and all encoding parameters plus optional features like encryption. These set-up groups are configured via simple to use M.S. Windows’s applications usually by technical leads. GMS’ receivers have a similar control scheme. This approach allows pre-configuration of the link such that all you need to do is set-up the TX and RX to the same configuration group number and the link is properly set-up. This control approach provides system-level ease of operation. There is an optional Remote Control Unit (RCU) or the FCON (field controller) available so the operator can conveniently access all features of the VHPT from a remote location (such as the cockpit of an aircraft). 4.2 Power Amplifiers (Standard or VEPA) The VETA comes with either the VEPA or the Standard power amplifier. The VEPA (Very Efficient Power Amplifier) is Cobham/GMS’ newest design specifically targeted for CODFM modulation formats because of its high linearity and efficiency. Most of the connections using either the VEPA or the Standard PA are the same. Where there are differences they are pointed out in the manual. In addition if there are differences in specifications they are also noted. 4.3 Applications VHPT Transmitters can be used in following environments:

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• Helicopter Links • UAV/UGV Applications • High-Security Surveillance Applications • Repeater Transmitter • Mobile and Portable AV Applications

4.4 Key System Features

• Up to 15W Linearized Output Power • Robust Link Performance with COFDM, (Optional 400 or 2K Carriers) • Bandwidths 6, 7, 8 MHz standard, 1.25 MHz, 2.5 MHz optional • Small, Rugged Enclosure • Secure – Optional128/256 bit Encryption AES • Output Frequency: 1.7 to 5.0 GHz (In-Bands) • Low System Latency (~44mS) • Built-in MPEG-2/4 Encoder • User Data Option • +12Vdc or +28Vdc Option • Companion VETA Receiver Diversity Reception

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5. Initial Check Out

The standard VHPT kit includes the following items: VHPT unit VHPT Power cable (GMS P/N 780-C0219) VHPT Audio cable (GMS P/N 780-C0516) VHPT Data/Control cable (GMS P/N 780-C0518)

(Data, Control interfaces) NOTE: Based on customer application GMS may deliver additional cables and antennas. Contact GMS for further information. The VHPT is pre-configured by GMS prior to shipment (based on customer requirements), thus is ready to work “right out of the box”.

5.1 Getting Started Prior to installing a VHPT unit into the desired target environment, an initial checkout should be performed to ensure proper operation of the unit. The initial checkout consists of configuring a basic HP-VDL (High Power VETA Digital Link). Any VETA series Receiver can be used.

Figure 1 – Basic HP-VDL Setup

Figure 1 shows a basic interconnection configuration to establish a wireless HP-VDL. NOTE: Receivers, down converters (D/C) units and their associated hardware are sold separately. The steps necessary to set up the HP-VDL are described below.

Install omni-directional antennas onto the VHPT RF output port and Down- Converter (D/C) RF

input port.

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Note: Transmitters should not be powered on without a load. Doing so could cause irreversible damage to the equipment. A proper heat sink is also required. Attach the power cable (780-C0219X1) to the VHPT unit. Attach a RF cable from the D/C IF output port to RF in port of the receiver. Attach a composite video source to VHPT BNC video input (marked CVBS/Y). Attach a video

cable from one of the BNC video output ports on the receiver to a video monitor. To prepare to power the VHPT unit, attach the red and black wires of the power cable to +12V

(or +28V) terminal and ground of power supply, respectively. NOTE: The power supply (for the transmitter) with the Standard PA needs to be able to provide at least 12 Amps of current at a nominal +12Vdc input if configured for +12Vdc input. (6 Amps if configured for +28Vdc input). With the VEPA PA the power supply needs to be able to provide at least 7 amps at a nominal +12Vdc input if configured for +12Vdc input (3.5 amps if configured for +28Vdc input). Turn on the video source and video monitor equipment. Apply power to the VHPT and the receiver unit. Also ensure the down converter is powered

(+12 VDC to pin 1, GND to pin 3 of the DB-9 pin connector located on the bottom side of the D/C). If the down converter is installed in a pole mount box it will have a power switch on the side of the unit. Ensure the switch is turned to the “On” position.

Ensure that all setting on TX and RX sides are matching (RF Frequency, Bandwidth, Spectral Inversion and Guard Interval).

After approximately 20 seconds, the link should be established and video provided by the source should be displayed on the monitor.

(See corresponding Receiver manual.) The initial checkout described above is simply to check the basic video operation of the VHPT unit. For further details on monitoring and controlling the VHPT using GMS’ optional MS Windows-based VETA TX Configurator software program, see corresponding manuals listed in Appendix A.

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6. Hardware Overview 6.1 VHPT Connectors

Figure 2 shows the Hardware configuration of VHPT.

6.1.1 DC IN (J8) Connector Type: 4 pin PTO, Male. The VHPT accepts +12 or +24Vdc input voltage (depending on configuration). GMS cable (780-C0219) is used to connect to the DC in connector. See drawing 100-C0219 for power connections (Appendix A). Pin outs for this connector is shown in the table below.

Table 1 Connector J8 PTO-4 Pin Connection A +Vdc B +Vdc C GND D GND

6.1.2 RF OUT (J1) Connector Type: N, flange mount, Female Note: Transmitters should not be powered on without a load. Doing so could cause damage to the output PA. A proper heat sink is also required.

Figure 2 – VHPT Front View

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6.1.3 DATA/CONTROL (J6) Connector Type: 10pin PTO, Male The Data/Control port provides a two-port interface of RS-232 signals. The RS232 Data port is designed for user data input. The RS232 Control port is used for control and monitoring of the VHPT unit using GMS’ MS Windows-based Configurator software program. GMS cable (780-C0518) is used to connect to the Data/Control connector. See drawing 100-C0518 for RS232 and Data connections (Appendix C). In addition a +12Vdc out signal (pin A) is provided to power a remote control unit such as the RCU or the FCON which are optional purchased hardware. Special cables are provided when using a remote control unit (reference the Appendix cable drawings, 100-C0257 or 100-C0549). Pin outs for this connector are shown in the table below.

Table 2 Connector J6 PTO-10 PIN Connection A +12Vdc Out B NC C NC D GND E DATA-TX F DATA -RX G GND H CTRL-TX J CTRL-RX K GND

6.1.4 AUDIO (J7) Connector Type: 10pin PTO, Female Two channels (Audio1, Audio2) of unbalanced audio input are provided. GMS cable 780-C0516 is used to connect to the Audio connector. See drawing 100-C0516 for connections (Appendix B). Pin outs for this connector are shown in table below. Connections for the Standard and VEPA power amplifier are slightly different. There are no FWD and REV PWR DET connections for the VEPA power amplifier.

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Table 3 Connector J7 PTO-10 PIN Connection Standard PA Connection VEPA PA A FWD PWR DET NC B REV PWR DET NC C Audio-R Audio-R D NC NC E NC NC F GND (for Audio-R) GND(for Audio-R) G Audio-L Audio-L H NC NC J NC NC K GND (for Audio-L) GND (for Audio-L)

6.1.5 Y/CVBS (J2) Connector Type: BNC-F This connector is used as an input connector for Composite Video. 6.1.6 SDI (Optional) (J3) Connector Type: BNC-F This input is used for SDI (Serial Data Interface). This is an optional feature and can be purchased at additional cost.

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7. Software Overview 7.1 System requirements

VHPT are based on SDMT Transmitter. Configuration, control and monitoring of the VHPT unit are accomplished by using GMS’ optional (sold separately) MS Windows-based SDMT Configurator software program. This Graphical User Interface (GUI) program provides the end user with a straightforward way to interface with the VHPT. During normal operation, once a HP-MDL link is established, the SDMT Configurator GUI does not need to be active and can be disconnected from the VHPT. The SDMT Configurator program has been developed and tested on Windows 2000, Windows XP and Windows NT. Although the SDMT Configurator program may work properly on other operating systems, only the Windows 2000, Windows XP and Windows NT environments have been used at GMS and no support or assistance can be provided concerning other operating systems. The physical connections from the VHPT box to a PC using the Data/Control cable (780-C0518) are shown below. Attach this cable to the DATA/CONTROL connector on the VHPT. The “CTRL” connector brings out the RS-232 TX and RX lines so that a PC with a COM port can be used. An USB to RS-232 adapter can be purchased if the PC only has USB ports available.

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Figure 3 – PC Control Connections

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7.2 Installation The following instructions outline the installation process for the VHPT Configurator program:

• Insert provided CD-ROM into computer. • Click on ‘setup.exe’ file. This will launch the GMS_SDMT Configurator Setup program and

several initial setup files will begin to be copied onto the computer. • After the initial setup files are copied over, the GMS_SDMT Configurator Setup program will

prompt the user to close any applications that are running. Once all other programs are exited, click on the ‘OK’ button.

• The GMS_SDMT Setup program will prompt the user to click on the ‘computer icon’ button to begin installation. If desired, the user can change the destination directory from the default. Click on the ‘computer icon’ button.

• The GMS_SDMT Setup program will then prompt the user to ‘Choose Program Group’. If desired, the user can change the program group from the default. Click on the ‘Continue’ button.

• After installing the SDMT Configurator program, it will display a window indicating that setup was completed successfully. Click ‘OK’.

Refer to corresponding manual 100-M0143 for details how to operate the VETA TX Control SW.

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8. Specifications COFDM RF Output Output Frequency: 1.7 to 5.0 GHz (In-Bands) Bandwidth: Selectable 6, 7, 8 MHz

(1.25 MHz, 2.5 MHz Optional) RF Output Power: Up to 15 W (Model Dependent) Video Encoding Input: Composite, S-Video Standards: NTSC (with and without pedestal) or PAL Compression Standard: MPEG-2 or MPEG-4 Part 2 Chrominance Profile: 4:2:0 or 4:2:2 Line Standard: 525 and 625 Horizontal Resolution: 704 pixels Vertical Resolution: 576 (625 line), 480 (525 line) Systems Latency1 end to end delay: 44 ms Audio Encoding Analogue Audio Inputs:

Dual, Line-Level or Mic-Level, Single-Ended, Clip Level 12 dB

User Selectable MPEG or NICAM encoding RS232 Data Input Baud Rate: Up to 115kBaud. Modulation Modulation Type: COFDM w/QPSK or 16QAM FEC: 1/2, 2/3, 3/4, Guard Intervals2: 1/32, 1/16, 1/8, 1/4 Spurious: 52dBc COFDM Carriers: 400 (optional) or 2k Carriers Security Option The VHPT can optionally be provided with Advanced Encryption System (AES) 128/256 for protecting the signal in sensitive applications User Data Option Protocol: RS-232C, Asynchronous, 8 Bits, No Parity, 1 Stop Bit Data Rate: Selectable, Up to 38.4KBaud User Data PID: Selectable Connectors RF Output: N-F Video Composite/ Y: BNC-F

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Audio: p/o PT02E-12-10P (ref. Section 5.1.4) Control: p/o PT02E-12-10P (ref. Section 5.1.3) DC Power: PT02E-12-4P (ref. Section 5.1.1)

Pin A & B: +Vcc Pin C & D: GND

Physical Dimensions: 8” (W) x 10.25” (D) x 2.08” (H) 20.32 cm x 26.04 cm x 5.28 cm Weight: 8.45 lbs (3.83kgs) Environmental: Operational Temperature: -10 to 70 deg C Humidity: Up to 95% non-condensing DC Power DC Voltage Range3:

24-32Vdc @ 5 Amps (opt) Standard PA 24-32Vdc @ 3.5 Amps (opt) VEPA PA 9-15Vdc @ 10 Amps (opt) Standard PA 9 -15Vdc @ 7 Amps (opt) VEPA PA

Control USB-1 or RS-232 control port via the supplied MS Windows based control application. Remote Control Unit (RCU or FCON) is available. 1 Modulation mode and decoder dependent 2 May be limited in certain modes 3 Model dependent

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100-M0155X1A 21 of 27

GMS Inc. doing business as Cobham Tactical Communications and Surveillance www.cobham.com/tcs

Appendix A– References

For more detailed information on GMS products described in this manual, download the manuals below from GMS’ WEB site (www.cobham.com/gms) of contact GMS customer Service department.

• Operations Manual, VETA Receivers:VR 100-M0087 • MVMR 100-M0146 • MVRD 100-M0144 • Operations Manual, VETA Receiver SW 100-M0131 • Operations Manual, VETA Transmitter 100-M0118 • Operations Manual, VETA Transmitter SW 100-M0143

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REVISIONS

ECO REV DESCRIPTION DATE APPROVED

SIZE DATE DWG NO REV

PROD 12/22/04 100-C0219X1A X1A

QC SCALE NONE SHEET 1 OF 1

DRAWN SLP

ENG/TECH

ENG

DWG TITLE

CABLE,EXTERNAL,P8,MHPT

NOTES:1. REFERENCE BOM 780-C0219X1A FOR PART REFERENCE DESIGNATORS (SHOWN AS [] ON DRAWING)AND DESCRIPTIONS.

2. DIMENSIONS SHOWN ARE INCHES.

3 LABEL FINAL CABLE ASSEMBLY WITH PART NUMBER 780-C0219X1A USING BEST COMMERCIAL METHOD.

CABLE ASSEMBLY INSTUCTIONS

4. CUT 2 PIECES OF HEATSHRINK [SLV2] TO 0.50 AND COVER TRIMMED ENDS OF CABLE [W1] JACKET. SHRINK HEATSHRINK [SLV2]. RE-ATTACH P8 STRAIN RELIEF TO CONNECTOR BODY. REFERENCE FIGURE 4.

5. ATTACH BANANA PLUGS [P1] AND [P2] TO CABLE [W1] WIRES AS SHOWN IN FIGURE 5. LABEL CABLE ASSEMBLY WITH PART NUMBER (REFERENCE NOTE 3) AND "DC POWER" USING BEST COMMERICIAL METHOD, APPROXIMATELY WHERE SHOWN. REFERENCE FIGURE 5.

W1

P1

P2

WHT

BLK

3

3. REMOVE STRAIN RELIEF AND COMPRESSION GASKET FROM [P8] CONNECTOR BODY. ROUTE WIRES THROUGH COMPRESSION GASKET AS SHOWN IN FIGURE 3. COVER ENDS OF WIRES WITH 0.25 LENGTH OF HEATSHRINK [SLV1]. SOLDER WIRES TO CONNECTOR [P8]. COVER SOLDER JOINT WITH HEATSHRINK AND SHRINK HEATSHRINK. REFERENCE FIGURE 3.

2. CUT WIRES [W2] AND [W3] TO DIMENSIONS AS SHOWN IN FIGURE 2. STRIP AND PRE-TIN WIRES AT BOTH ENDS.

1. CUT CABLE [W1] TO 48.0. TRIM CABLE JACKET TO EXPOSE WIRES AS SHOWN. STRIP WIRES AT BOTH ENDS AND PRE-TIN

AT 0.75 END ONLY. REFERENCE FIGURE 1.

FIGURE 5

FIGURE 1

W1

48.0

0.150 0.503.000.75

PRE-TIN THIS END ONLY

1.50

W2

0.150 0.1501.50

W3

0.150 0.150

FIGURE 2

FIGURE 3

A

B

C

D

W1

BLK

WHT

W2

W3

P8

SLV1 4X

P8 CONNECTOR

BODY

STRAIN

RELIEF

W1

SLV2 SLV2P8 CONNECTOR

BODY

P8 STRAIN RELIEF

FIGURE 4

E0285X1 X1 INITIAL RELEASE 12/22/04 SLP

COMPRESSION

GASKET

COMPRESSION

GASKET

E0438 X1A UPDATE DWG TO REFLECT AS BUILT 07/08/05 SLP

GMS Products

MikeK
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Appendix B – Cable, Power
MikeK
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REVISIONS

ECO REV DESCRIPTION DATE APPROVED

SIZE DATE DWG NO REV

PROD 08/02/2010 100-C0516X1 X1

QC SCALE NONE SHEET 1 OF 2

DRAWN RM

ENG/TECH

ENG

DWG TITLE

CABLE, VHPT, AUDIO UNBALANCED

NOTES:1. REFERENCE BOM 780-C0516X1 AND OR LATEST MINOR REVISION FOR PART REFERENCE DESIGNATORS (SHOWN AS [] ON DRAWING)AND DESCRIPTIONS.

2. DIMENSIONS SHOWN ARE INCHES.

3 LABEL FINAL CABLE ASSEMBLY WITH PART NUMBER 780-C0516X1 USING BEST COMMERCIAL METHOD APPROXIMATELY WHERE SHOWN

CABLE ASSEMBLY INSTRUCTIONS

E1441 X1 INITIAL RELEASE 08/02/2010

TOLERANCESUNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHESDO NOT SCALE DRAWING

LINEARX.X = ± 0.5

X.XX = ± 0.125X.XXX = ± 0.020

GMS Products

W1

3. SOLDER THE CENTER CONDUCTOR OF CABLES [W1] AND [W2] TO THE THROUGH HOLE CENTER PIN OF CONNECTORS [P1] AND [P2]. SOLDER THE CABLE SHIELD OF [W1] AND [W2] TO THE THROUGH HOLE GROUND PIN OF THE CONNECTORS [P1] AND [P2]. REFER TO FIGURE 3. THEN SLIDE THE HEAT SHRINK [SLV1] INTO THE CABLES [W1] AND [W2] AS CLOSE AS POSSIBLE TO THE CENTER PIN OF THE CONNECTOR AND SHRINK IT.

SLV1

FIGURE 3

GROUND PIN

CENTER PIN

HEADER

W2

1. CUT CABLES [W1] AND [W2] TO 36.00 ±0.50 LENGTH AS SHOWN IN FIGURE 1.

2. STRIP AND PRE-TIN WIRES AS SHOWN IN FIGURE 2. TRIM JACKET TO EXPOSE FOIL SHIELD AND WIRES. CUT FOIL SHIELD FLUSH WITH CABLE JACKET.

36.00 ±0.500.70

FIGURE 1

0.100

SHIELD DRAIN WIRE FIGURE 2

W1

0.100

SHIELD DRAIN WIRE

W2

W1 W2

P7 CONNECTOR STRAIN RELIEF

COMPRESSIONGASKET

P7

W2

W1

KJHGFEDCBA SLV7

FIGURE A

MikeK
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Appendix C – Cable, Audio
MikeK
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23 of 27
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REVISIONS

ECO REV DESCRIPTION DATE APPROVED

SIZE DATE DWG NO REV

PROD 08/16/2010 100-C0518X1 X1

QC SCALE NONE BOM: 780-C0217X4 SHEET 1 OF 1

DRAWN RM

ENG/TECH

ENG

DWG TITLE

CABLE,VHPT, EXTERNAL DATA/CONTROL

NOTES:1. REFERENCE BOM 780-C0518X1 AND OR LATEST MINOR REVISION FOR PART REFERENCE DESIGNATORS (SHOWN AS [] ON DRAWING) AND DESCRIPTIONS.

CABLE ASSEMBLY INSTRUCTIONS

3. IF ATTACHED, REMOVE STRAIN RELIEF AND COMPRESSION GASKET FROM CONNECTOR [P6]. ROUTE WIRES FROM TWO CABLES [W1] THROUGH COMPRESSION GASKET AND COVER WIRES WITH 0.25 LENGTH HEATSHRINK [SLV1]. SOLDER WIRES TO CONNECTOR [P6] AS SHOWN IN FIGURE 3. COVER SOLDER JOINT WITH HEATSHRINK AND SHRINK HEATSHRINK. THREAD CABLES THRU [P6] STRAIN RELIEF CLAMP AND SNUGGLY TIGHTEN CLAMP AROUND CABLES.

1. CUT 2 PIECES OF CABLE [W1] TO 36.00 ±0.50. PERFORM STEPS 1 AND 2 TO BOTH PIECES OF CABLE [W1]. AT ONE END, TRIM CABLE JACKET AND FOLD CABLE SHIELD BACK OVER JACKET TO EXPOSE WIRES. AT OTHER END, TRIM CABLE SHIELD FLUSH WITH CABLE JACKET. CUT WHITE WIRE FLUSH WITH CABLE JACKET AT BOTH ENDS. STRIP WIRES AND PRE-TIN AS SHOWN. REFERENCE FIGURE 1.

2. PRE-TIN EACH CABLE [W1] SHIELD. MAKE A SHIELD DRAIN WIRE, 2 EACH, AS SHOWN USING WIRE [W3]. PRE-TIN BOTH ENDS. SOLDER DRAIN WIRES [W3] TO CABLE SHIELD. COVER SHIELD WITH 0.5 LENGTH OF HEAT SHRINK [SLV2] AND SHRINK HEATSHRINK. REFERENCE FIGURE 2.

4. COVER TRIMMED END OF CABLE JACKET [W1] DATA AND [W1] CTRL WITH 0.50 LENGTH HEATSHRINK [SLV2] AND SHRINK HEATSHRINK. COVER WIRES WITH 0.25 LENGTH HEAT SHRINK [SLV1] AND SOLDER WIRES TO CONNECTORS [P1] AND [P2] AS SHOWN IN FIGURE 4. COVER SOLDER JOINT WITH HEATSHRINK AND SHRINK HEAT SHRINK.

5. ATTACH BACKSHELLS [SH1] TO CONNECTORS [P1] AND [P2]. LABEL BACKSHELL FOR [P1] WITH "DATA", LABEL BACKSHELL FOR [P2] WITH "CTRL" USING BEST COMMERICIAL METHOD. LABEL [P6] CONNECTOR WITH "P6", USING BEST COMMERICIAL METHOD. REFERENCE FIGURE 5.

TOLERANCESUNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHESDO NOT SCALE DRAWING

LINEARX.X = ± 0.5

X.XX = ± 0.125X.XXX = ± 0.020

E1441 X1 INITIAL RELEASE 08/16/2010

FIGURE 1

36.0

0.150 0.1000.500.75

CABLE SHIELDTRIM CABLE

SHIELD

ABCDEFGHJK

10X

RED

REDYEL

YEL

BLK

BLK

SHIELD DRAIN WIRE

FIGURE 3

ABCDEFGHJK

RED

RED

YEL

YEL

BLK

BLK

1

95

876

432RED

YEL

BLK1

95

876

432RED

YEL

BLK

3X

FIGURE 4

DATA

CTRL2

FIGURE 5

FIGURE 21.30

SHIELD DRAIN WIRE

0.400.150

COMPRESSIONGASKET

2 LABEL FINAL CABLE ASSEMBLY WITH PART NUMBER 780-C0518X1 USING BEST COMMERCIAL METHOD, APPROXIMATELY WHERE SHOWN.

SH1

W1

W1 W1SLV2

W1

P6

SLV1

P6

SLV2SVL1

P1

SLV2

P1

P2

P6

SVL1 3X

SH1

CTRL

DATA

P2

DATA

CTRL

W3

GMS Products

W1 2X

W1

W1

MikeK
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Appendix D – Cable, Data/Control
MikeK
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24 of 27
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REVISIONS

ECO REV DESCRIPTION DATE APPROVED

SIZE DATE DWG NO REV

PROD 03/10/2011 100-C0549X1 X1

QC SCALE NONE SHEET 1 OF 1

DRAWN RM

ENG/TECH

ENG

DWG TITLE

CABLE,VHPT, FCON CONTROL

NOTES:1. REFERENCE BOM 780-C0549X1 AND OR LATEST MINOR REVISION FOR PART REFERENCE DESIGNATORS (SHOWN AS [] ON DRAWING) AND DESCRIPTIONS.

CABLE ASSEMBLY INSTRUCTIONS

4. IF ATTACHED, REMOVE STRAIN RELIEF AND COMPRESSION GASKET FROM CONNECTOR [P2]. ROUTE WIRES FROM CABLE [W1] THROUGH COMPRESSION GASKET AND COVER WIRES WITH 0.25 LENGTH HEATSHRINK [SLV1]. SOLDER WIRES TO CONNECTOR [P2] AS SHOWN IN FIGURE 4. COVER SOLDER JOINT WITH HEATSHRINK AND SHRINK HEATSHRINK. THREAD CABLES THRU [P2] STRAIN RELIEF CLAMP AND SNUGGLY TIGHTEN CLAMP AROUND CABLES.

1. CUT A PIECES OF CABLE [W1] TO 36.00 ±0.50. AT ONE END, TRIM CABLE JACKET AND FOLD CABLE SHIELD BACK OVER JACKET TO EXPOSE WIRES. AT OTHER END, TRIM CABLE SHIELD FLUSH WITH CABLE JACKET. CUT WHITE WIRE FLUSH WITH CABLE JACKET AT BOTH ENDS. STRIP WIRES AND PRE-TIN AS SHOWN. REFERENCE FIGURE 1.

2. PRE-TIN CABLE [W1] SHIELD. MAKE A SHIELD DRAIN WIRE, AS SHOWN USING WIRE [W3]. PRE-TIN BOTH ENDS. SOLDER DRAIN WIRES [W3] TO CABLE SHIELD. COVER SHIELD WITH 0.5 LENGTH OF HEAT SHRINK [SLV2] AND SHRINK HEATSHRINK. REFERENCE FIGURE 2.

6. SOLDER WIRES TO CONNECTORS [P1] AS SHOWN IN FIGURE 6. COVER SOLDER JOINT WITH HEATSHRINK [SLV1] AND SHRINK HEAT SHRINK. SLIDE HEATSHRINK [SLV2] OVER EXPOSED CABLE JACKETS AND SHRINK IT.

TOLERANCESUNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHESDO NOT SCALE DRAWING

LINEARX.X = ± 0.5

X.XX = ± 0.125X.XXX = ± 0.020

E1603 X1 INITIAL RELEASE 03/10/2011

FIGURE 1

36.0

0.150 0.1000.500.75

CABLE SHIELDTRIM CABLE

SHIELD

ABCDEFGHJK

REDYELBLK

SHIELD DRAIN WIRE

FIGURE 4

ABCDEFGHJK

RED

YELBLK

FIGURE 5

CTRL2

FIGURE 7

FIGURE 21.30

SHIELD DRAIN WIRE

0.400.150

COMPRESSIONGASKET

2 LABEL FINAL CABLE ASSEMBLY WITH PART NUMBER 780-C0549X1 USING BEST COMMERCIAL METHOD, APPROXIMATELY WHERE SHOWN.

W1

W1 W1

SLV2

P2

SLV1

P2

P1P2

W3

GMS Products

W1

4

5321

YEL

4X

P1W1

W2

RED

BLK

3. CUT A PIECE OF CABLE [W2] TO 36.00 ±0.50. TRIM CABLE JACKET AS SHOWN IN FIGURE 3. STRIP AND PRE-TIN WIRES.

FIGURE 3

36.0

0.150 0.1000.500.75

W2

RED

BLK

REDBLK

W2

CT x2

RED

BLK

8. FILL THE GAP BETWEEN CONNECTOR BODY AND [SLV2] WITH SMALL AMOUNT OF EPOXY AND LET IT DRY. FIT THE PREASSEMBLY INTO THE CONNECTOR HOUSING USING APPROPRIATE TOOLING SCREW ON THE COLLET NUT WITH APPROPRIATE TORQUE. ENSURE CABLING IS NOT PINCHED DURING ATTACHMENT. SLIDE HEATSHRINK [SLV3] OVER CONNECTOR BODY APPROXIMATELY 0.5" AND SHRINK HEAT SHRINK. REFERENCE FIGURE 7.

5. SLIDE THE FOLLOWING ONTO THE CABLE: 0.50 LENGTH OF HEATSHRINK [SLV3], COLLET NUT, COLLET AND 0.5 LENGTH OF HEATSHRINK [SLV2]. PRIOR TO SOLDERING COVER INDIVIDUAL WIRES WITH 0.25 LENGTH OF HEATSHRINK [SLV1]. REFERENCE FIGURE 5.

FIGURE 6

SLV3

P2

9. LABEL CABLE ASSEMBLY WITH PART NUMBER AND ATTACH CABLE TIES APPROXIMATELY WHERE SHOWN, USING BEST COMMERICIAL METHOD. REFERENCE FIGURE 7.

SLV3

SLV2

SLV2 SLV1

7. ARRANGE THE CONTACT-CONDUCTOR ASSEMBLIES ACCORDING TO INSERT MARKING, AVOIDING ANY TWISTING OF THE CONDUCTORS. POSITION THE MIDPIECE WITH WINDOW ON THE INSULATOR NOTCH AND THE SECOND MIDPIECE TO FORM A CYLINDER. PUSH THE COLLET SO THAT THE TAG OF MIDPIECE IS POSITIONED IN THE SLOT OF COLLET.

SLV3

x5

MikeK
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Appendix E – Cable VHPT, FCON Control
MikeK
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25 of 27
MikeK
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MikeK
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MikeK
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100-M0155X1A
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REVISIONS

ECO REV DESCRIPTION DATE APPROVEDNOTES:1. REFERENCE BOM 780-C0257X3 FOR PART REFERENCE DESIGNATORS (REFERENCED AS [ ] ON DRAWING) AND DESCRIPTIONS.

2 LABEL FINAL CABLE ASSEMBLY WITH PART NUMBER 780-C0257X3 USING BEST COMMERCIAL METHOD, APPROXIMATELY WHERE SHOWN.

3 LABEL CONNECTOR DESIGNATION, WITH TEXT SHOWN NEXT TO NOTE CALLOUT, USING BEST COMMERCIAL METHOD, AS CLOSE TO CONNECTOR AS APPLICABLE.

SIZE DATE DWG NO REV

PROD B 05/07/10 100-C0257X3 X3

QC SCALE NONE SHEET 1 OF 2

DRAWN SLP

ENG/TECH

ENG

DWG TITLE

CABLE,ACTUATOR/CBOX/RCU, INTERFACE

TOLERANCESUNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHESDO NOT SCALE DRAWING

LINEARX.X = ± 0.5

X.XX = ± 0.125X.XXX = ± 0.020

E0387X2 X1 INITIAL RELEASE 12/13/05 SLP

ASSEMBLY INSTRUCTIONS

1. CUT CABLE [W1], STRIP CABLE JACKET AND WIRES AS SHOWN IN FIGURE 1. PRE-TIN ALL WIRES.

FIGURE 1

4. REMOVE CONNECTOR STRAIN RELIEFS FROM CONNECTORS [P1], [P2] AND [P4]. SLIDE STRAIN RELIEF OVER EACH END OF CABLE AS SHOWN IN FIGURE 4. COVER ENDS OF ALL WIRES AT EACH END OF CABLE WITH 0.250 LENGTH OF HEATSHRINK [HS1]. SOLDER WIRES TO CONNECTORS AS SHOWN IN FIGURE 4. COVER SOLDER JOINT WITH HEATSHRINK AND SHRINK HEATSHRINK.

FIGURE 4

A

B

C

D

E

F

G

H

J

K

WHT

RED

GRN

BRN

BLK

A

B

C

D

E

F

G

H

J

K

WHT

RED

GRN

BRN

BLK

P1

P2W10.500.150 0.50 0.150

26.0 FEET ± 2 INCHES

W1

2. CUT CABLE [W2], STRIP CABLE JACKET AND WIRES AS SHOWN IN FIGURE 2. PRE-TIN ALL WIRES.

3. CUT CABLE [W3], STRIP CABLE JACKET AND WIRES AS SHOWN IN FIGURE 3. PRE-TIN ALL WIRES.

0.500.150 0.50 0.1502.00 FEET ± 2 INCHES

W3FIGURE 3

0.500.150 0.50 0.15028.0 FEET ± 2 INCHES

W2FIGURE 2

N/C

N/C

N/C

N/C

N/C

N/C

N/C

N/C

STRAIN RELIEF

RED

BLK

1

2

3

4

5

6

7

8

9

RED

GRN

RED

P3

N/C

N/C

N/C

N/C

N/C

A

B

C

D

E

F

G

H

J

K

RED

GRN

BLK

P4

N/C

N/C

N/C

N/C

N/C

N/C

N/C

W3

W2STRAIN RELIEF

STRAIN RELIEF

BLK

BLK

E1238 X2 CHANGE CONNECTOR 07/16/09 CWO

E1431 X3 CHANGE CONNECTOR 05/07/10 RM

GMS PRODUCTS

MikeK
Typewritten Text
Appendix F – Cable, Actuator,Cbox,RCU, Interface
MikeK
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26 of 27
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MikeK
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MikeK
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REVISIONS

ECO REV DESCRIPTION DATE APPROVEDNOTES:1. REFERENCE BOM 780-C0129X2 FOR PART REFERENCE DESIGNATORS (REFERENCED AS [ ] ON DRAWING) AND DESCRIPTIONS.

2 LABEL FINAL CABLE ASSEMBLY WITH PART NUMBER 780-C0129X2 USING BEST COMMERCIAL METHOD, APPROXIMATELY WHERE SHOWN.

3 LABEL DESCRIPTION AS SHOWN USING BEST COMMERCIAL METHOD, APPROXIMATELY WHERE SHOWN.

SIZE DATE DWG NO REV

PROD B 12/29/03 100-C0129X2 X2

QC SCALE NONE SHEET 1 OF 1

DRAWN SLP

ENG/TECH SM

ENG

DWG TITLE

CABLE,RCU2000, DB9 (FM-M) & PWR

TOLERANCESUNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHESDO NOT SCALE DRAWING

LINEARX.X = ± 0.5

X.XX = ± 0.125X.XXX = ± 0.020

ASSEMBLY INSTRUCTIONS

1. CUT CABLE [WP1] AND STRIP CABLE JACKET AS SHOWN. STRIP AND PRE-TIN WIRES. REFERENCE FIGURE 1.

WP1

48.00.50

0.1002.000.50

FIGURE 1

2. ATTACH BANANA PLUGS [P2] AND [P3] TO 2.00 STRIPPED END OF CABLE [WP1]. ATTACH [P2] TO RED WIRE, ATTACH [P3] TO BLACK WIRE. REMOVE BANANA PLUG CASING AND FORM WIRE THRU HOLE IN BANANA PLUG. SOLDER WIRE TO PLUG, TRIM EXCESS WIRE AND RE-ATTACH CASING. REFERENCE FIGURE 2 AND DETAIL A.

CASING

BANANA PLUG

WIRE

WP1

P2

RED WIRE

BLACK WIRE P3

DETAIL AFIGURE 2

3. CUT CABLE [WP2] AND STRIP CABLE JACKET AS SHOWN. TRIM SHIELD AND WRAPPING FLUSH WITH CABLE JACKET END, LEAVING SHIELD DRAIN WIRE SAME LENGTH AS WIRES. STRIP AND PRE-TIN WIRES AND SHIELD DRAIN WIRE. REFERENCE FIGURE 3.

4. COVER ENDS OF WIRES FROM [WP2] WITH 0.25 LENGTH OF HEATSHRINK [HS1]. SOLDER WIRES AND SHIELD DRAIN WIRE TO CONNECTOR [J1] AS SHOWN. COVER SOLDER JOINT WITH HEATSHRINK [HS1] AND SHRINK HEATSHRINK. COVER TRIMMED END OF CABLE JACKET WITH 1.00 LENGTH OF HEATSHRINK [HS2] AND SHRINK HEATSHRINK. REFERENCE FIGURE 4.

WP2

24.0

0.100 0.1000.75 0.75

FIGURE 3

FIGURE 4

1

95

8

7

6

4

3

2BLK

RED

SHIELD

WP2

HS13X

HS2J1

1

95

8

7

6

4

3

2

RED

RED

BLK

BLKSHIELD

HS14X

P1

HS2

5. COVER UN-TERMINATED ENDS OF CABLES [WP1] AND [WP2] WITH 1.00 LENGTH OF HEATSHRINK [HS2]. COMBINE SHIELD DRAIN WIRE FROM [WP2] AND BLACK WIRE FROM [WP1] AND COVER WITH 0.25 LENGTH OF HEATSHRINK [HS1]. COVER REMAINING WIRES WITH HEATSHRINK [HS1] AND SOLDER WIRES TO CONNECTER [P1] AS SHOWN IN FIGURE 5. COVER SOLDER JOINTS WITH HEATSHRINK [HS1] AND SHRINK HEATSHRINK. ALIGN TRIMMED ENDS OF CABLES [WP1] AND [WP2] AND COVER WITH HEATSHRINK [HS2]. SHRINK HEATSHRINK [HS2]. REFERENCE FIGURE 5.

FIGURE 5

6. ATTACH D-SUB BACKSHELLS [SH1] TO D-SUB CONNECTORS [P1] AND [J1], PER DETAIL B. ATTACH CABLE TIES [CT1] WHERE SHOWN. REFERENCE FIGURE 6 AND DETAIL B.

CABLE JACKET

STRAIN RELIEF

D-SUB CONNECTOR

SH1

DETAIL B

P1

SH1

SH1

J1

P2

P3

FIGURE 6

3.018.0

23 P1

3 DC POWER

3 RS232

E0232X1 X1 INITIAL RELEASE 12/29/03 SM

E0232X4 X2 ADD P2, P3, UPDATE DWG FORMAT 10/10/05 SLP

WP2

WP1

GMS Products

MikeK
Typewritten Text
Appendix G – Cable, RCU2000, DB9 (FM-M) & PWR
MikeK
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27 of 27
MikeK
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