FLEXCOMM MULTIBAND FM COMMUNICATIONS SYSTEM © INSTALLATION MANUAL PATENT NUMBER: 4,189,689 MANUAL PART NUMBER: 158-0088-000 REVISION A THE COMMUNICATIONS PROFESSIONALS Ponted in USA WULFSBERG 1300 West 89th Street + Overiana Park, Kansas 66214 ELECTRONICS, INC. teiepnone(91) 432 000 eon WUD 424042 WOLESBERG OLPKWULFSBERG ELECTRONICS FLEXCOMM TED_ONE YEAR WARRANTY Wulfsberg Electronics, Inc. (hereinafter called WEI), Overland Park, Kansas has designed, engineered and constructed the equipment with the finest material and components available. This equipment has been thoroughly inspected and tested before leaving the factory. WEI warrants each item of new equipment manufactured by it to be free from defects in design, workmanship and material under normal use for which intended for one year after date of installation. WEI will hereunder replace or repair (at WEI's discretion) any WEI part or component, which shall within such warranty period, be returned, transportation charges prepaid, to an authorized warranty Service center. Such service centers, if authorized in advance by WEI, may return the part or unit to WEI's factory for compliance with this warranty. This warranty of parts includes bench time required to locate the defect, repair same or replace such part. This warranty shall not apply to any unit or part thereof, which has not been installed by a WEI approved installation facility in accordance with the Installation instructions, or which has been repaired or altered in anyway so as to adversely affect its performance or which has been subjected to misuse, negligence or accident. This warranty is expressly in lieu of all other warranties, expressed or implied, Including any implied warranty of merchantability or fitness and of all other obligations or liabilities on the part of the seller. WEI reserves the right to make changes in design or additions to or improvements in its equipment without obligation to install such additions or improvements in equipment theretofore manufactured.WULFSBERG ELECTRONICS FLEXCOKM SUBJECT TABLE OF CONTENTS DESCRIPTION AND OPERATION wa 1.2 1.3 14 Purpose of Equipment... .. +... 2+ -- Design Features. . 1.3.1 Transceivers. 2... ee ee eee 1.3.2 Control Unit... . 2... 00. ae Technical Characteristics... ....--...-- Pape ee VW11 General. 2... ee eee V.W.1.2 Transmitter. ©... ee ee 1.4.1.3. Main Receiver. 2... cee 1.4.1.4 Guard Receiver... . 12 eee VHS Optios.. 2.2... eee eee VWAL2 CHIPS GREE ces he ee ee (EnseiiP eboney ee . Tia ia: Thandattten ee 1.4.2.3 Main Receiver... ee ee ee 1.4.2.4 Guard Receiver... ee ee ee 1.4.2.5 Options. 6. eee eee ee eee V4.3 ATMO. ee ae eee VHB. Generale oe ee eee 1.4.3.2 Transmitter. 6.6 ee eee 1.4.3.3. Hain Receiver... 2. + sae PAGE ii Rev.AWULFSBERG ELECTRONICS FLEXCOMM TABLE OF CONTENTS (cont.) SUBJECT PAGE 1, DESCRIPTION AND OPERATION (cont.) 1.4.3.4 Guard Receiver... 5... oN nn The C-200.. 0.0, we A Sy et mn VHS C1000. eee eee eee 12 1.5 System Components... -. 2.2. eee ee ee 1-12 1.6 Test Equipment and Accessories... 2.2... “ 1-15 11. INSTALLATION 20 General. ee ee eee sae 21 om 2.2 Unpacking and Inspecting Equipment... .. 2... 2-1 2.3. Installation - MT-210 Mounting Tray... 2.2... 0 21 2.4 Installation, Multipin Crimp Connectors and Coax Connectors, Socket and Crimp Tool Information. . . « 2-5 2.5 Installation - Transceivers... ... 0.00 .: 2-5 2.6 Installation - Control Unit... 2... see 2-9 2.7 Installation - Antennas... .. . cee eee Rg 2.8 Installation - Wiring Considerations... . . . oe 2-23 2.8.1 Channel Lines... 2... See oe 2-23 2.8.2 Tone A,B,C, 0D, EE... 2... 20, see 2-24 2.8.3 Main Tone Enable... 2.2... 00, see 2-25 2.8.4 on/off... . pee eens see 2-25, 2.8.5 Main RX Audio Disable)... -....... 2-25 ~ 2.8.6 Guard RX Audio Disable... 2... 2.20. 2-25 iii Rev.AWULFSBERG ELECTRONICS FLEXCOMH LIST OF ILLUSTRATIONS FIGURE TITLE PAGE 2.341 FLEXCOMM Transceiver Outline... ........ . 2-3/4 2h "N' Series Assembly Instructions for RG-58.... . 2-6 24-2 "N" Series Assembly Instructions for RG8/U.... . 2-7 24-3 BNC Series Assembly Instructions for RG-58A/U. . . . 2-8 2.6-1 C200 QutHiMR ss ne 2-10 2.6-2 C-1000 Outline... 2... ee ee we 2-112 2.7-1 AT-30 Outline. 2.2... . ee ee ee see 2-13 2.7-2 AT-31 Outline... we ee ee ee ee 2-14 2.7-3 AT-230 Installation (Sheet 1 of 2)......... 2-15 227-3 AT-230 Installation (Sheet 20f 2)......... 2-16 27-4 AT-270 Outline. . 2... me ee eee 2-17 2.7-5 AT-461 Outline. 2. ee ee ee ee 2-18 2.7-6 AT-690 Outline. . 2... wee eee wee 2-19 207-7 AT-960 Out bee ee ee ee ee 2-21/22 2.8-1 FLEXCOMM FM System... ....... wee wee 2-30 2.8-2 FLEXCOMM FM Multiple Band System... .. . . tee 2-31 2.8-3 FLEXCOMM FM Channel Memory Discretes... .... . 2-32 2.8-4 FLEXCOMM FM Encode/Decode Considerations... . . . 2-33 2.85 Typical HA-4 PTT Installation... 2... ee + 3h 2.8-6 Typical Mic Jack Connection... ...... tee 2-35 2.8-7 FLEXCOMM FM Wiring Diagram... 2... 2.2. 20s 2-37/38 2.9-1 HA~4 Outline. 2... ee ee ee see 2-39 2.9-2 €-963 Outline... 2 ee Se ee ee Reo 2.9-3 SPHO Outline... 2... wee see RM v Rev.Awa 1.2 1.3 WULFSBERG ELECTRONICS FLEXCOMM SECTION 1 DESCRIPTION AND OPERATION INTRODUCTION This manual contains information pertaining to the Installation and operation of the FLEXCOMH TRANSCEIVER SYSTEM. PURPOSE OF EQUIPMENT The FLEXCOKM TRANSCEIVER SYSTEM is designed to provide two-way FM communications in the VHF Lo-band, VHF Hi-band, UHF Lo-band and UHF Hi-band. DESIGN FEATURES The FLEXCOMM TRANSCEIVER SYSTEM was designed to yield maximum rellability and flexibility while maintaining ease of operation, maintenance and installation. 1.3.1 TRANSCEIVERS =~ All FLEXCOMM TRANSCEIVERS interchangeable within the system wiring and mounting tray. v> Multiple FLEXCOMM TRANSCEIVERS may be connected in parallel to provide multiband communications from a single Control Unit. => Optional single channel Guard Receiver Module. =* 32 erystal. controlled sub-audible CTCSS tones are built- in. “> Plug-in modular construction with bifurcated gold card~ edge connectors. = Epoxy impregnated fiberglass printed circuit boards with post coating for humidity and dust protection. -- Al solid state. => Burn-out resistant transmitter. =~ RF gated audio side tone exists when transmitter is producing RF power.WULFSBERG ELECTRONICS FLEXCOKM 1.3 DESIGN FEATURES (cont. TRANSCEIVERS (cont. ) 1.3.1 1.3.2 Automatic signal-to-noise squelch with manual override. audio. Input and output (without pre-emphasis phasis) for external CTCSS tones, tone bursts, DTMF encoders, voice scranblers, data, etc. Operates on 28V DC power. Low profile aviation package. No band spread limitation. CONTROL UNITS All FLEXCOMM Control Units Interchangeable within the system wiring. alk 32 (C-200) or 30 (C-1000) pre-set simplex or push-to- duplex channels. Programmable memory uses EAROM (Electrically Alterable Read Only Memory). May be programmed to control any FLEXCOMM SYSTEM TRANS- CEIVER. Each preset channel programmable to low or high band VHF or UHF frequencies. SynthesIzed CTCSS tone code programmable for each transmit and/or receive frequency. Five progranmable discrete switches (40 ma max.) per channel for switching external devices. Guard channel transmit frequencies programmed Into memory. Main Transcelver controls. Guard Receiver controls. Mode selector -- Main or Guard or both Recelvers active. CTCSS tone disable. Integral lighting, 5 or 28V.WULFSBERG ELECTRONICS FLEXCOMM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS Vad RT-30 VA GENERAL SPECIFICATION Model Designation: Frequency Range: Channeling: Tunabi lity: Mode: Physical Dimensions: Weight (incl. mounting tray) Mounting: Power Requirements: Voltage: Current: Standby: Receive: Transmit: Control: Temperature: Storagi Operati Altitude: Certification: CHARACTERISTICS RT-30 29.70 - 49.99 Miz 20 KHz under Part 90 Capable of 10 KHz incremental tuning Simplex or Semi-duplex, 16F3 4.38 in. (11.1 cm) Wx 10.5 in. (26.7 em) L x 5 in. (12.7 em) H 7.5 Ibs (3.40 kg) without Guard RCVR. 8.3 Ibs (3.76 kg) with Guard RCVR. Fixed mounting tray ( any position) 27.5 VOC, +20% TA Max. TA Max. 2.44 Max. Remote with a FLEXCOMM Control Unit 0 ° ~552C to +852 -hoPc to +60°C 51,000 ft MSL FCC Parts 15, 90WULFSBERG ELECTRONICS FLEXCOMM 1.4.1.2. TRANSMITTER SPECIFICATION Nominal Output Power: Output Power Tracking: Output Impedance: Duty Cycle: Frequency Stability: Modulation: Audio Input: Audio Distortion: Modulation Tracking: Sidetone Output: Microphone: FM Hum and Noise: Harmonics: Spurious: 1.4.1.3 MAIN RECEIVER Usable Sensitivity: Quieting Sensitivity: Adjacent Channel: 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont.) 1.4.1 RT-30 (cont. CHARACTERISTICS 10 watts +20 to -35% from nominal over frequency range 50 ohms Cont inuous +0.0005% (-40°C to +60°C) #5 Kiz deviation, Limited (0.25 VRHS into 200 ohms input circuit for +3 KHz. Shop adjustable, 30 nV to 0.6 VRKS. 5% Max. #0.6 dB over frequency range 3.3 mW into 600 ohms. Adjustable, 0.01 mi to 100 mh Carbon or equivalent 3768 -58 dB below carrier level -80 dB below carrier level 0.6 uV, 12 dB SINAD (EIA) 1.0 uV, 20 dB quieting (EIA) -70 dB EIA (20 KHz, EIA)WULFSBERG ELECTRONICS FLEXCOKM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont) V..1 RT-30 (cont) 1.4.1.3 MAIN RECEIVER (cont. SPECIFICATION CHARACTERISTICS Intermodulation: 60 dB EIA (20 Kiz, EIA) Spurious Responses: -80 dB Image Response: -75 dB Modulation Acceptance: 6 KHz minimum (EIA) ‘Squelch: Threshold Setting: 8 dB SINAD or less Tight Setting: 21 dB SINAD or more Audio Output: 33 ml into 600 ohms. Shop adjustable, 0.01 to 100 miv Audio Distortion: 5% (EIA) Frequency Tolerance: +#0.001% ovgr tempergture Fange (-40°C to +60°C) Hum and Noise: -35 dB Unsquelched -45 dB Squelched T.4.1.4 GUARD RECEIVER 80 dB EIA (20 KHz) Adjacent Channel: Intermodulation: -70 dB EIA (20 KHz) Other specifications same as the Main Receiver 1.4.1.5 OPTIONS Guard Receiver, One (1) Channel, Crystal-Control led Plug-in-Assembly. Guard Receiver CTCSS Decoder, Programmable Guard Receiver Tones. Rev.AWULFSBERG ELECTRONICS FLEXCOMM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont. 1.4.2 RT-138* 1.4.2.1 GENERAL ‘SPECIEICATION Model Designation: Frequency Range: Channelling: Tunability: Mode: Physical Dimensions: Weight (incl. mounting tray) Mount ing: Power Requirements: Voltage: Current: Standby Rece Transmi Control: Temperature: Storage: Operate: Altitude: Certification: * Preliminary Speci fications CHARACTERISTICS RT-138 138.0000 - 173.9975 MHz 25 KHz or 30 kHz under Part 90 Capable of 2.5 Kiz incremental tuning Simplex or Semi-dup! 16F3 4,38 in. (11.1 om) W in, (26.7 om) Lx 5 (12.7 em) 7.5 Ibs (3.40 kg) wi Guard RCVR. 8.3 Ibs (3.76 kg) wi Guard RCVR. Fixed mounting tray position) 27.5 VOC, +20%, IA Max. 1A Max. 2.28 Max. Remote with a FLEXCO! Control Unit 9, °, -552C to +8590 -ho°C to +60°%C 51,000 Ft MSL FCC Parts 15, 74, 90 ex, x 10.5 thout th (any HMWULFSBERG ELECTRONICS FLEXCOMM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont) 1.4.2 RT=138% 1.4.2.2 TRANSMITTER SPECIFICATION CHARACTERISTICS Nominal Output Power: 10 watts Output Impedance: 50 ohms Duty cycle: Continuous Frequency Stability: +0.0005% (-40°C to +60°C) Modulation: +5 KHz deviation, Limited Audio Input: 0.25 VRMS into 200 ohms input circuit for +3 KHz. Shop adjustable, 30 mv to 0.6 VAMS. Audio Distortion: 5% Max Modulation Tracking: 40.6 dB over frequency range Sidetone Output: 3.3 mW into 600 ohms. Adjustable, 0.01 mi to 100 ni Microphone Carbon or equivalent Harmonics: -70 dB below carrier level Spurious: -80 dB below carrier level 1.4.2.3 WAIN RECEIVER Usable Sensitivity: 0.35 uv, 12 dB SINAD (EIA) (precludes Guard option) 0.5 uv, 12 dB SINAD (EIA) Quieting Sensitivity: 1.0 uv, 20 dB quieting (EIA) Adjacent Channel -70 dB EIA (30 KHz, EIA) * Preliminary SpecificationsWULFSBERG ELECTRONICS FLEXCOMM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont.) 1.4.2 RT-138% (cont.) 1.4.2.3 HAIN RECEIVER (cont. SPECIFICATION CHARACTER! STICS Intermodulation: 60 dB EIA (30 KHz, EIA) Spurious Responses: -85 4B Image Response: -80 4B Modulation Acceptance: 7 KHz minimum (E1A) Squel ch: Threshold Setting: 6 dB SINAD or less Tight Setting: 21 dB SINAD or more Audio Output: 33 mW into 600 ohms. Shop adjustable, 0.01 to 100 mW Audio Distortion: 5% (EIA) Hum and Noise: =35 dB Unsquelched -45 dB Squelched 1.4.2.4 GUARD RECEIVER Adjacent Channel: -75 dB EIA (30 KHz) Intermodulation: ~65 dB EIA (30 Kitz) Other specifications same as the Main Receiver 1.4.2.5 OPTIONS Guard Receiver, One (1) Channel, Crystal-Controlled Plug-in-Assenbly. Guard Receiver CTCSS Decoder, Programmable Guard Receiver Tones. Increased Sensitivity 0.35 uV, 12 dB SINAD (EIA); pre~ cludes the use of a Guard Receiver. * Preliminary SpecificationsWULFSBERG ELECTRONICS FLEXCOMM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont.) 50% Fm 2 13 RI 1.4.3.1 GENERAL SPECIFICATION CHARACTERISTICS Model Designation: Frequency Range: 50-0000 - 469.9875 MHz Channeling: 25 KHz under Part 90 Tunabi lity: Capable of 12.5 KHz incremental tuning Mode: Simplex or Semt-duplex, 16F3, Physical Dimensions: 4.38 in. (11.1 em) W x 10.5 in, (26.7 om) Lx 5 in. (12.7 em) H Weight (incl. mounting 7.5 Ibs. (3.40 kg) without tray) Guard RCVR. 8.3 Ibs (3.76 kg) with Guard ROVR. Mounting: Fixed mounting tray (any position) Power Requirements: Vol tage: 27.5 VOC, +208 Current: Standby 1A hax. Receive: 1A Max. Transmit: 2.28 Max. Contro Remote with a FLEXCOMM Control Unit Temperature: ° 5 Storage: 75540 to +850¢ Operate: 40°C to 460°C Altitude: 51,000 ft MSL Certification: FCC Parts 15, 74, 90 * Preliminary Specifications Rev.AWULFSBERG ELECTRONICS FLEXCOMM. 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont.) 1.4.3 RT-450% (cont.) 1.4.3.2 TRANSMITTER SPECIFICATION CHARACTERISTICS Nominal Output Power: 10 watts Output_Impedance: P-ohas, (eo Frequency Stability: +0.00025% (-40%C to +60°c) Modulation: 45 Kiz deviation, Limited Audio Input: 0.25 VRMS into 200 ohms Input circuit for +3 KHz. Shop adjustable, 30 mV to 0.6 VRMS. Audio Distortion: 5% Modulation Tracking: 40.6 dB over frequency range Sidetone Output: 3.3 mW into 600 ohms. Adjustable, 0.01 aW to 100 ni Microphone: Carbon or equivalent Harmonics: -65 dB below carrier level Spurious: 80 dB below carrier level 1.4.3.3. MAIN RECEIVER Usable Sensitivity: 0.4 uv, 12 dB SINAD (EIA) (precludes Guard Receiver Option) 0.6 uv, 12 dB SINAD (EIA) Quieting Sensitivity: 1.0 uv, 20 dB quieting (EIA) Adjacent Channel: -65 dB EIA (25 Kiz, EIA) * Preliminary Specifications I-10 Rev.AWULFSBERG ELECTRONICS FLEXCOMM 1.4 TECHNICAL CHARACTERISTICS STANDARD TEST CONDITIONS (cont.) 1.4.3) RT-450% (cont. 1.4.3.3 MAIN RECEIVER (cont.) SPECIFICATION CHARACTERISTICS Intermodulation: 60 dB EIA (25 KHz, EIA) Spurious Responses: -80 dB Image Response: -80 48 Modulation Acceptance: 7 kHz minimum (EIA) Squelch: Threshold Setting: 6 4B SINAD or less Tight Setting: 21 dB SINAD or more Audio Output: 33 mv into 600 ohms. Shop adjustable, 0.01 to 100 mh Audio Distortion: 5% (Ela) Hum and Noise: -30 dB Unsquelched -45 dB Squelched 1.4.3.4 GUARD RECEIVER Adjacent Channel: -75 dB EIA (25 kHz) intermodulation: -65 dB EIA (25 KHz) Image Response: -75 dB Other spec: same as the Main Receiver 1.4.3.5 OPTIONS Guard Receiver, One (1) Channel Crystal-Controlled Plug-in=Assenbly. Guard Receiver CTCSS Decoder, Programmable Guard Receiver Tones. Tncreased Sensitivity 0.4 uV, 12 dB SINAD (EIA); precludes the use of a Guard Receiver. 1.4.4 C-200 - Dzus rail mounting 5.75 in. (14.6 em) Wx 2.25 in. (5.7 cm) Hx 4.3 in. (10.9 em) D. Weight 1.4 Ibs. (0.635 kg) * Preliminary Specifications 1-1 Rev.AWULFSBERG ELECTRONICS FLEXCOMM 1.5 SYSTEM COMPONENTS (cont.) MODEL NO. RT-450-1 em2, RT-450-3 C-200-1 Fy | C-1000-1 6-963 HA-4-110 HA-H= 111 HA-4=112, HAnH= 113 HA=H= 114 HA-4-210 HA-H-211 HA-4=212 HA=4-213 DESCRIPTION UHF Band Transceiver w/Guard Module 450.000-469.9875 MHz UHF Band Transceiver w/Guard Module and Guard Module CTCSS Tone 450.000-469.9875 MHz UHF Band Transceiver, w/Increased Sensi ty. (Precludes Guard) 450.0000-469.9875 Miz Control Unit w/2BV Lights Control Unit W/5V Lights Control Unit w/28V Lights Control Unit w/5V Lights Tone Burst Encoder Handset and Hanger: Includes Hanger, Matching Modular Coil Cord and Modular FM PTT (switched mic) Handset Light Ash Beige White Black Ivory Same as above but with Clear Fire Retardant Coil Cord Light Ash Beige White Black WEI PART NUMBER 400-0103-001 400: 103: 400-0103-003 400-0099-000 400-0099-001 400-0106-000 400-016-001 490-0068-000 400-0101-110 400-0101-111 4o0-0101-112 4o0-0101-113, 4o0-0101- 114 400-0101-210 400-0101-211 400-0101-212 400-0101-213 1-13 Rev.AWULFSBERG ELECTRONICS FLEXCOMM 1.5 SYSTEM COMPONENTS (cont.) MODEL NO. A421) ‘sP-40 M-66T AT-30 AT-31 AT=230 AT-270 AT-461 AT-690 AT-960 IN-200-0 IN-210-0 *IN-210-1 *P-19, *MT-210 PAT Py DESCRIPTION Ivory Auxiliary Speaker and Amplifier Noise Cancelling Microphone Antenna, VHF Lo-Band 30-88 MHz Antenna, VHF Multiband 30-50 MHz, 118-152 NHz, 138-174 MHz Antenna, VHF Lo-Band Tunable (Narrow-Band 200 KHz) 29-50 MHz Antenna, UHF Rod and Ball 450-470 MHz Antenna, UHF Jet Blade 450-470 MHz Antenna, VHF Hi-Band, 17" whip 138-174 HHz Antenna, VHF Hi-Band Blade 138-174 KHz Installation Kit (P-200) FLEXCONM Transceiver Installation Kit FLEXCOMM Connector Kit, 61 S (P210) Type "IN Plug for 58 A/U FLEXCOMM Rigid Mounting Tray Type "'N" Plug for RG 8/U Type “BNC! Plug for RG 58 A/U WEL PART NUMBER 400-0101-214 400-0040-000 137-002-000 121-015-000 121-016-000 121-005-000 121-002-000 121-011-000 121-004-000 121-0010-000 149-0058-000 149-0059-000 149-059-001 129-014-000 300-2194-000 129-004-000 129-0025-000 ‘Included in the IN-210-0 FLEXCOMM Transceiver Installation Kit. 1-14 Rev.AWULFSBERG ELECTRONICS FLEXCOMH 1.6 TEST EQUIPMENT AND ACCESSORIES The following are test equipment and accessories built by Wulfsberg Electronics for testing of the FLEXCOMM TRANSCEIVER SYSTEM. MODEL NO. DESCRIPTION WEL PART NUMBER PR+200 Programmer 400-0100-000 TSH-200 FLEXCOHM Test Harness 149-060-000 Ec-200 Power Supply/Guard Receiver 149-061-000 Extender Card Ec-201 RT-30 Synthesizer Extender Card 149-062-000 EC-202 Audio Board Extender Card 149-063-000 1-15 Rev.A21 2.2 2.3 WULFSBERG ELECTRONICS FLEXCOMH SECTION 11 INSTALLATION GENERAL, This section contains instructions and considerations for the Proper installation of the FLEXCOMM TRANSCEIVER SYSTEM, The information presented herein is necessary for the proper operation and satisfactory performance of the equipment. UNPACKING AND_INSPECTING EQUIPMENT Physically compare the presence of each item in the shipment with that shown on the packing list. Exercise care when unpacking each unit. Make a visual inspection of each unit for evidence of damage incurred during shipment. If a claim for damage is to be made, save the shipping container to substantiate the claim. When all equipment is unpacked, it is suggested the carton and packing materials be saved for possible reshipment. INSTALLATION ~ MT-210 MOUNTING TRAY The Mounting Tray, which in turn captivates the Transceiver, may be mounted in any convenient location. Allow sufficient room at the front for cable and connector routing. The mount is secured to the mount- ing surface with Number 10 or 1/4 x 20 machine screws or equivalent and appropriate lock nuts. See Figure 2.3-1 for mounting dimensions. NOTE: The system has been vibration, temperature and altitude tested to assure performance in aircraft environments. However, controlled environments improve the system reliability. This factor should be considered when selecting a remote site.WULFSBERG ELECTRONICS FLEXCOMM, tine bt Bor 40) re (i i lo.a2 wax ‘aeaes) | a aw lo Le | | teen” | | | 302 iss) (2) /e os, 3 Loy. Jt i ey See waco! Leg, aa __ oa ren aooae) FLEXCOMM TRANSCEIVER OUTLINE FIGURE 2.3-1 2-3/4= a | 2 __yes" it ana To om Ar sow auano | aateslarens 2% [deh din R730 w70 ouano | 28185] 40ne | 2 ula [ee3al iM St od2.4 2.5 WULFSBERG ELECTRONICS FLEXCOMM INSTALLATION - MULTIPIN CRIMP CONNECTORS AND COAX CONNECTORS SOCKET AND CRIMP TOOL INFORMATION Socket No. 20, WEI Part Number 129-1041-000 Bendix Part Number 10-257982-20F or equivalent Crimp Tools Daniels Number H 22520/1-01 Daniels Number 4 22520/1-01 Turret or equivalent Balmar 55-000 with 55-102 Head Assy. Insertion Tool Balnar Part Number AT 1068 or equivalent Extraction Tool Balmar Part Number AT 20 or equivalent BNC Crimp Tool -~ ITT Cannon Number 15520-5002 or MIL-T-M22910/7-17 or equivalent INSTALLATION - TRANSCEIVERS FLEXCOMM TRANSCEIVERS are totally interchangeable within the installation. The Transcelver should be secured in the mounting tray and the antenna cable should be attached firmly to insure proper connector mating. See Figure 2.3-1 for mounting dimensions. The multiturn sidetone adjustment Is accessible through the Front Panel of the Transceiver without removal of the unit or the dust cover. This facilitates varying the sidetone level from the factory setting to accomodate variations in the installation or the user's desired listening level. NOTE: The sidetone should be adjusted to a level that yields the desired audio level without causing feedback when used with the cabin speaker.WULFSBERG ELECTRONICS eubseiee (CABLE “NUT. GASKE FEMALE. Ra sue css tag wasn: CLAMP eA 2. Comb out brold ond trim delete to dimension shown, canter ‘conductor. Remove ences solder rr 3 Penton braid clamp gaint ovter locket ond fold breld over ‘braid clamp. Poalion cantor! fhah with dialectic ond elder fo 4. Slide coble ond cable hordware Inte body ond tighten until herp edge of brold camp spite groove goskar delle bit daca "NU SERIES ASSEMBLY INSTRUCTION FOR RG 58 FIGURE 2.4-1(1D wutrseere EvecTRoNics FLEXCOMM WASHER CLAMP, M1 § © Nur GASKET : fa} eg a tA ae MALE, CONTACT a Place nut and goskel, wth “V" groove teword clamp, over cable and cut jacket 1 dimension shown, Comb out sion shows. Tin heat. ‘id ond fold out. Cut eable dielectric 10 dimen- ter conductor, wing minimum amount of Pull braid wires forward ond taper toward center conductor. Place clam over braid ond push botk cable jacket. Not Fold back broid wires es shown, trim to proper ‘engih ond form over clamp at shown. For RG-62 and 71 U type cable ‘add bushing. Solder contoct to center conductor, aveiding excessive heat which might swell cable dielectric "IN" SERIES ASSEMBLY INSTRUCTIONS FOR RG 8/U FIGURE 2.4-2 2-7WULFSBERG ELECTRONICS FLEXCOMM oo ” coer STEP Cut cable to dimensions shown. Slide ferrule onto cable fs shown, Slide the crimp assembly over the dielectric and under © ° the braid unt the dielectric butts against the Insulator at Point D. Trim excess braid wire even with the nut Shoulder at point E. Slide ferrule over the braid, butting jalnst the nut shoulder at point F. Crimp ferrule over braid using tne proper crimp tool. Solder center ' to cable conductor as shown. Remove ext ‘rom outside of contac. —. STEPS Insart assembly into connector body, Tighten securely with @ wrench, BNC SERIES ASSEMBLY INSTRUCTIONS FOR RG-5S8 A/U FIGURE 2.4-3 2-8(1 wutrseenc ELECTRONICS 2.6 2.7 FLEXCOMM INSTALLATION - CONTROL UNIT The Control Units are designed to mount on dzus/rails per MIL MS-25213. The FLEXCOMM Control Units are interchangeable except for depth and helght and will control any FLEXCOMM TRANSCEIVER or combination of Transceivers. See Figures 2.6-1 and 2.6-2 for mounting dimensions. INSTALLATION - ANTENNAS The appropriate antenna should be selected to match the Transceiver frequency band and should be mounted on the bottom of the aircraft if at all possible. It is most important that the UHF antenna be mounted on the bottom because the antenna is subject to antenna shadowing similar to DME and Transponder antennas. Should pressure or moisture seal be required, a bead of sealant such as Dow Corning RTV-738 should be applied to the outside perimeter of the mounting surface. See Figures 2.7-1 through 2.7-7 for antenna mounting dimensions.(UD) wutessene ELECTRONICS FLEXCOMM pasr9| oe8| 5 s7ouax 46.08) +200 OUTLINE FIGURE 2.6-1 2-10WULFSBERG ELECTRONICS FLEXCOMM nores | OMENSONS PARENTHESES ARE. MRLLMETERS, | STANDARO 0205 RAL. MOUNT FEF AML. STD. S282. 1000 OUTLINE FIGURE 2.6-2 2-11/12 7 Rev.A