Service Bulletin

523-0815459-001000
PP11230
CABIN SYSTEMS

TAILWIND 560 SYSTEM

FUSELAGE MOUNTED UNIT (FMU) (CPN 932000-201)

SERVICE BULLETIN 1

OVER ROTATION AND PCU SKEW ANGLE FIX

TRANSMITTAL INFORMATION SUMMARY

Summary

This is the original release of SB 1 for the Tailwind 560 System Fuselage Mounted Unit (FMU).

Service Bulletin Revision History

REVISION DATE OF RELEASE

Initial Release February 16, 2007

NOTE: This service bulletin may be installed only by Rockwell Collins or an authorized Collins Service Center.

NOTICE

INFORMATION SUBJECT TO EXPORT CONTROL LAWS

The technical data in this document (or file) is controlled for export under the Export Administration Regulations (EAR), 15
CFR Parts 730-774. Violations of these laws may be subject to fines and penalties under the Export Administration Act.

© Copyright, 2007 Rockwell Collins, Inc., All rights reserved

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Service Bulletin

Software License and General Conditions of Sale

For each software license procured, the Software License for Equipment Specific Software, reproduced below, shall apply.

Software License for Equipment Specific Software

Software delivered hereunder, either embedded in equipment described herein or specifically designed for use in or with such
equipment, is copyrighted by the seller and shall remain the sole and exclusive property of seller. Seller grants the buyer a perpetual,
worldwide, non-exclusive license to use the software only in or with the equipment. The buyer shall not copy, modify, or disassemble
the software, or permit others to do so. Buyer shall not transfer the license granted hereby or possession of the software except as part
of or with the equipment, such transfer being subject to the restrictions contained herein. Seller may terminate this license upon written
notice for violation of any of the terms of the foregoing license.

Should the customer have any questions concerning the scope of permitted use, please contact your Rockwell Customer Service Engineer.

Rockwell Collins’ General Conditions of Sale 074-8431-866 (Rev 10/00) are incorporated herein by reference.

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1. Planning Information

A. Effectivity

The modification procedure described in this service bulletin applies to the equipment
listed below.

COLLINS APPLICABLE TO PRODUCTION INSTALLED

UNIT
PART NUMBER SERIAL NUMBERS SERIAL NUMBERS
FMU 932000-201 All Units with Manufacturing Date of
February 15, 2007 and Later

NOTE: The modification contained in this service bulletin is applicable to all future status(es)
of the equipment Type Number.

B. Concurrent Requirements

None required.

C. Reason
(1) Condition Modification Affects
The Gimbal Elevation drive can experience a failure resulting in loss of elevation
control allowing the antenna assembly to exceed the permitted swept-range.
Exceeding the swept-range represents a safety concern since there is a possibility
that components of the antenna assembly can come in contact with mounting plate
and/or skin of the aircraft resulting in potential damage to the aircraft.
When selecting manual control of the FMU, the Polarization Conversion Unit (PCU)
skew angle will go to zero degrees. This prevents auto alignment of the FMU.

(2) Extent Condition Encountered

Affects all FMU’s (P/N 932000-201).

(3) Scope of Modification

This is a permanent change.

(4) Expected Benefits of Modification

The current design intentionally drives the Rotor into the Stator on the Elevation motor
Drive Assembly. These two components (Rotor and Stator) had design margins
less than the peak drive loads of the drive chain. Adding a hard stop dowel pin
into the Elevation Arm and a slot into the Pivot Pin Side Drive (Sprocket) will add a
secondary stop that will not allow the Antenna Assembly components to go outside
the swept-range and damage the mounting plate or aircraft skin. This redundant stop
will eliminate safety concerns as related to software failure.
Correcting the software so that the skew angle reacts appropriately when the FMU is
in manual control will allow auto alignment of the FMU.

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D. Description

Replace Elevation Arm PAU1472 Revision “A” with Revision “B”

Replace Pivot Pin Drive Side (Sprocket) P/N 65-111-4000-01 revision “B” with Revision “C”

Replace (2) Elevation Drive Belts P/N PAU7145 Revision “-“

Replace Software for Antenna Control Unit (ACU) version .005.000.007, P/N 65-113-1131
Rev. “G” with software .005.000.009, P/N 65-113-1131 Rev “H” for the Polarization
Conversion Fix.

E. Compliance

Mandatory with a compliance date of May 15, 2007.

F. Approval

The FMU (CPN 932000-201) modification and the design data has been FAA approved.

This service bulletin is not FAA approved.

G. Labor
(1) Elevation Arm Removal and Replacement.
Estimated: 2.0 labor hours disassemble, inspection, re-assemble.

(2) Pivot Pin Drive Side (Sprocket) Removal and Replacement.

Estimated: 1.0 labor hour disassemble, inspection, re-assemble.

(3) Elevation Drive Belt (2) Removal and Replacement.

Estimated 2.0 labor hours disassemble, inspection, re-assemble.

(4) FMU Software Download Procedure

Estimated: 10 minutes.

(5) FMU Acceptance Test Procedure.

Estimated: 6.0 labor hours.

H. Weight and Balance

Not affected.

I. Electrical Load Data

Not affected.

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J. Software Accomplishment Summary

Not applicable.

K. References

Rockwell Collins DBS Antenna Fuselage Mount Unit (FMU)/Enhanced Fuselage Mount
Unit (EFMU) component maintenance manual (repair manual), (CPN 523-0813851).

Rockwell Collins Tailwind 560 Installation Manual, (CPN 523-0813917).

Rockwell Collins Document PAU1001REF1.

Rockwell Collins Document 100122-205.

Rockwell Collins ECO-0097551, ECO-0097990.

Collins Avionics Standard Shop Practices Instruction Book (CPN 523-0768039).

L. Other Publications Affected

The next revision to the referenced component maintenance manual (repair manual) will
include the information contained in this service bulletin.

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2. Material Information

A. Cost and Availability

The charge to install this service bulletin will be labor and material as quoted by the
installing service agency.

The modification materials (described in paragraph 2.B) may be obtained from:

Rockwell Collins
Customer Response Center, M/S 133-100
400 Collins Road NE
Cedar Rapids, IA 52498-0001

TELEPHONE: 1.888.265.5467
INTERNATIONAL: 1.319.265.5467
FAX NO. 1.319.295.4941

Email: response@rockwellcollins.com

Orders must include quantity, Collins part number, and reference FMU Service Bulletin
932000-201-44-1. Parts are available for shipment within 30 days after receipt of order.

This service bulletin may be installed only by Rockwell Collins or an authorized Collins
Service Center.

The material and labor to incorporate this Service Bulletin will be provided free of charge.

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B. Material Required
Use the following materials to modify one FMU. List price column contains FOC for Free of
Charge.

PART NUMBER QTY LIST PRICE DESCRIPTION

PAU1472 Elevation Arm
1 FOC
Rev B
65-111-4000-01 Pivot Pin Drive Side (Sprocket)
1 FOC
Rev C
PAU7145 Elevation Drive Belt
2 FOC
Rev -
65-113-1131 Rev. “H” FMU Software
1 FOC
version .005.000.009.
780067 4 FOC Flat Washer
310-0048-000 4 FOC Flat Washer
Refer to the Rockwell Collins Services, Service Catalog (CPN 523-0766075) for list price updates.

C. Special Equipment or Tooling Required

None

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3. Accomplishment Instructions

A. Modification Procedure

CAUTION: THIS EQUIPMENT CONTAINS ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS) COMPONENTS THAT CAN BE DAMAGED BY STATIC VOLTAGES
PRESENT IN MOST REPAIR FACILITIES.

NOTE: For detailed repair/cleaning instructions, refer to Collins Avionics Standard Shop
Practices Instruction Book.

NOTE: For detailed assembly/disassembly instructions, refer to Rockwell Collins DBS

Antenna Fuselage Mount Unit (FMU)/Enhanced Fuselage Mount Unit (EFMU)
component maintenance manual (repair manual) (CPN 523-0813851).

(1) FMU Elevation Arm, Pivot Pin Drive Side (Sprocket) and Elevation Drive Belt
Replacement Procedures
(a) Remove the Antenna Assembly (P/N 65-120-0000-01) as follows: (Refer to
Figure 1)

1. Cut the two Elevation Drive Belts (P/N PAU7145). Refer to Figures 1 and 3.
2. Remove the Pin Plates (P/N 65-113-0000-01) shown in Figures 1 and 2 by
removing the eight 6-32 screws (P/N NAS1352C06-8) that go through the
tapped holes in the brackets that are attached to the Antenna Assembly
(P/N 65-120-0000-01). Retain Pin Plate and all screws.

(b) Remove the Elevation Arm (P/N PAU1472) and Pivot Pin Drive Side (Sprocket)
as follows:

1. Remove and the Elevation Motor (P/N 61-110-7100-02) by removing the

mounting hardware shown in Figure 4. Retain the Elevation Motor.
2. Remove the Elevation Arm (P/N PAU1472 Rev “A”) and Pivot Pin Drive
Side (P/N 65-110-4000-01 Rev “B”) by removing the mounting hardware
shown in Figure 4.

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(c) Reassemble the FMU as follows:

1. During reassembly of the FMU, ensure the following parts are replaced:

a. Replace the Elevation Arm P/N PAU1472 Rev “A” with Elevation Arm
P/N PAU1472 Rev “B”. Refer to Figure 6.
b. Replace the Pivot Pin Drive Side P/N 65-110-4000-01 Rev “B” with
Pivot Pin Drive Side P/N 65-110-4000-01 Rev “C”. Refer to Figure 5.
c. Replace the four Flat Washers (P/N 780076) with the four new Flat
Washers (P/N 780076). Refer to Figure 4.
d. Replace the four Flat Washers (P/N 780061) with the four new Flat
Washers (P/N 310-0048-000). Refer to Figure 4.

CAUTION: ENSURE THAT THE SPROCKET SLOT MATES WITH THE

ELEVATION ARM PIN DURING REASSEMBLY.
2. Install the Elevation Motor with the bracket, Elevation Arm, Pivot Pin Drive
Side (Sprocket), and Elevation Drive Belts in accordance with Rockwell
Collins Document 100122-205 and torque all hardware in accordance with
Rockwell Collins Document PAU1001REF1.
3. Place the two Elevation Drive Belts P/N PAU7145 around the larger and
smaller sprockets as shown in Figure 4.
NOTE: Arrange the belt splices in such a way that they are one to two teeth off
from one another on the Elevation Arm sprocket.

4. Attach the Elevation tensioning tool to set the tension on the belt.
5. Set the tension meter to read Hz and place the microphone of the meter
approximately 1/2 inch from the belt.
6. Using a small hex key, tap the belt near center of the open section and
measure. Measure both sides of the belt.
7. Adjust the motor, belts, and/or the tension tool as required to bring the
Tension meter readings for both sides of the top belt to within 30 Hz
of each other.
8. Get 10 readings from each side of the belt and record on a data sheet.
NOTE: Adjust tension to obtain readings that are approximately 280 to 310 Hz.
Throw out all data that is not consistent. The average range should fall
between 350 and 387 Hz (This is slightly higher than the recommended
tension. This slight over tension allows for a slight relaxation of the belts
after the tension tool is removed.).

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FMU Assembly
Figure 1

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Pin Plate
Figure 2

Elevation Drive Belt

Figure 3

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Elevation Arm and Pivot Pin Drive Side (Removal)

Figure 4

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Pivot Pin Drive Side (sprocket) P/N 65-110-4000-01 Rev. C

Figure 5

Elevation Arm P/N PAU1472 Rev. B

Figure 6

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Service Bulletin

(2) FMU Firmware Download Procedure

This procedure outlines the necessary steps to be performed in order to upgrade
firmware in the ACU on the FMU. The download is done by using a Windows PC
over an RS422 serial port with a terminal software tool such as Hyperterminal (or
equivalent). The RS422 port is a non-standard port for most PCs and therefore
depending on the desktop or laptop being used, an RS232 to RS422 Converter will
be required. This procedure uses a Test PC with an internal RS422 IO Card. A
test interface cable will be required to connect the RS422 serial bus and to provide
+28VDC power to the ACU being updated.
(a) Test Setup
A Unit Under Test (UUT) is connected to a Test PC and Power Supply via a Test
Interface Cable. Once powered up, the UUT gets new firmware downloaded into
it using a serial port software tool such as Hyperterminal or equivalent. After
downloading, the firmware is uncompressed using the pkunzip utility that resides
on the UUT itself. After power cycle, the UUT will be running its new firmware.

1. Equipment Required for the Firmware Download:

a. Test PC with RS422 port

b. 28 Volt DC Power Supply
c. Test interface cable 933435-100 or equivalent.
d. A single pole switch

2. Connect the equipment as follows:

a. Connect the RS422 connector on the cable to the Test PC RS422 port.
b. Connect the power supply positive (+) output to the single pole switch.
c. Connect the other end of the single pole switch to the 28VDC input on
the test interface cable.
d. Connect the negative (-) output of the power supply to the DC Return
input on the test interface cable.

3. Place a copy of the appropriate “zip” file (a560509.zip) into a convenient

directory on the Windows PC.
4. Connect the test interface cable (P/N 933435-100 or equivalent) from
the PC’s RS422 port to the FMU under test. DO NOT APPLY POWER
AT THIS TIME.

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CAUTION: TO PREVENT DAMAGE TO THE FMU, THE FOLLOWING STEP

"POWER SUPPLY REQUIREMENTS" MUST BE FOLLOWED.
5. Power Supply Requirements:

a. The input voltage must never ramp up or down slowly.

b. The input voltage must never be less than 18VDC.
c. To meet the above requirements, the DC Power Supply must be turned
"ON" PRIOR TO turning ON the switch between the power supply
positive (+) output and the 28 Volt DC input.

6. Make sure that the switch between the power supply positive (+) output
and the FMU is in the OFF position. Turn ON the power supply and set
the output to +28.0 VDC.
7. Launch Hyperterminal and configure the appropriate COM Port to 19200,
N, 8, 1.

(b) Download “ZIP” File to UUT

1. With the Hyperterminal open and configured, prepare to strike the “TAB”
key in order to break into the bootloader after power is applied to the UUT.
Turn the switch to the “ON” position
2. From Hyperterminal, strike the <tab> key multiple times as the UUT begins
to run during power-up. When complete, the boot monitor prompt (C:/$)
will be displayed. The Boot Monitor mode, which responds to a subset of
the DOS Command Prompt commands, is required for performing the
following steps.

a. Ensure the root directory is selected by entering “cd /” to the DOS

prompt.
b. Enter “upload” to the DOS prompt.
c. Using Hyperterminal, transfer the “a560509.zip” file by performing the
following step d.
NOTE: To transfer the “a560509.zip” file, the file must begin sending within
30 seconds of entering “upload” or the UUT will time-out and the
upload-transfer sequence must begin again.

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d. To complete the transfer, perform the following steps to upload the file:
- In the Hyperterminal tool bar, select TRANSFER > SEND FILE>
- Browse to the location of the file (a560509.zip) to be transferred
and select this file
- In the Protocol selection within the dropdown box, select Ymodem
- Select SEND. A Transfer box will appear showing the status of the
transfer.
e. Once the download is complete, unzip the file by entering
“call pkunzip –d –o a560509.zip” at the DOS prompt.
f. After the unzip process has finished, cycle power by setting the switch
to the OFF position, waiting 30 seconds and then turning the switch
back to the ON position.
g. Wait for the boot monitor message to appear and then verify the
firmware version by typing "$39,s". This will display the software
version. Verify that the version is 005.000.009
h. Set the switch to the OFF position.
i. Disconnect the test cable.

B. Testing Procedure

Test the unit in accordance with the test procedures in the Testing and Fault Isolation
section of the referenced component maintenance manual (repair manual).

C. Identification Procedure

NOTE: The identification procedure must be accomplished in order for the service bulletin
to be complete.
(1) Use permanent ink and mark out the MOD letter A on the unit modification plate.

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