KDR-610 - ISNTALL MANUAL - 006-10714-0000_0

7/27/2019 KDR-610 - ISNTALL MANUAL - 006-10714-0000_0

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INSTALLATION

MANUAL

KDR 610

XM Radio Weather Satellite

Receiver

MANUAL NUMBER 006-10714-0000

Revision 0 January, 2007


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Honeywell - ConfidentialTHIS DOCUMENT AND ALL INFORMATION AND EXPRESSION CONTAINED HEREIN ARE THE

PROPERTY OF HONEYWELL INTERNATIONAL INC., ARE PROVIDED IN CONFIDENCE, AND MAY BEUSED BY PERSONS REQUIRED BY 14 CFR 21.50 TO COMPLY WITH ANY OF THE TERMS OF THESEINSTRUCTIONS. EXCEPT AS SET FORTH ABOVE, NO PERSON MAY, IN WHOLE OR IN PART, USE,

DUPLICATE OR DISCLOSE THIS INFORMATION FOR ANY PURPOSE WITHOUT THE PRIORWRITTEN PERMISSION OF HONEYWELL INTERNATIONAL INC.

This document contains technical data and is subject to U.S. export regulations. These commodities,technology, or software were exported from the United States in accordance with the export

administration regulations. Diversion contrary to U.S. law is prohibited.


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Honeywell Materials License Agreement

The documents and information contained herein ("the Materials") are the proprietary data of

Honeywell International Inc. and Honeywell Intellectual Properties Inc. (collectively "Honeywell").These Materials are provided for the exclusive use of Honeywell Service Centers;

Honeywell-authorized repair facilities; operators of Honeywell aerospace products subject to an

applicable product support agreement, their wholly owned-subsidiaries or a formally designatedthird party service provider thereunder; and direct recipients of Materials from Honeywell'sAerospace Technical Publication Distribution. The terms and conditions of this License Agreementgovern your use of these Materials, except to the extent that any terms and conditions of another

applicable agreement with Honeywell regarding the operation, maintenance, or repair of Honeywellaerospace products conflict with the terms and conditions of this License Agreement, in which case

the terms and conditions of the other agreement will govern. However, this License Agreement willgovern in the event of a conflict between its terms and conditions and those of a purchase order or

acknowledgement.

1. License Grant - If you are a party to an applicable product support agreement, a Honeywell Service

Center agreement, or an authorized repair facility agreement, Honeywell hereby grants you a limited,non-exclusive license to use these Materials to operate, maintain, or repair Honeywell aerospace products

only in accordance with that agreement.

If you are a direct recipient of these Materials from Honeywell's Aerospace Technical PublicationDistribution and are not a party to an agreement related to the operation, maintenance or repair ofHoneywell aerospace products, Honeywell hereby grants you a limited, non-exclusive license to use these

Materials to maintain or repair the subject Honeywell aerospace products only at the facility to which theseMaterials have been shipped ("the Licensed Facility"). Transfer of the Materials to another facility owned

by you is permitted only if the original Licensed Facility retains no copies of the Materials and you provideprior written notice to Honeywell.

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license to use any Honeywell trademarks or patents is granted under this License Agreement.

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Materials.

4. Assignment And Transfer - This License Agreement may be assigned to a formally designated servicedesignee to the extent allowed under an applicable product support agreement or transferred to asubsequent owner or operator of an aircraft containing the subject Honeywell aerospace products.

However, the recipient of any such assignment or transfer must assume all of your obligations under thisLicense Agreement. No assignment or transfer shall relieve any party of any obligation that such party then

has hereunder.

5. Copies of Materials - Unless you have the express written permission of Honeywell, you may not makeor permit making of copies of the Materials. Notwithstanding the foregoing, you may make copies of onlyportions of the Material for your internal use. You agree to return the Materials and any copies thereof to

Honeywell upon the request of Honeywell.


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6. Term - This License Agreement is effective until terminated as set forth herein. This License Agreementwill terminate immediately, without notice from Honeywell, if you fail to comply with any provision of this

License Agreement or will terminate simultaneously with the termination or expiration of your applicableproduct support agreement, authorized repair facility agreement, or your formal designation as a third party

service provider. Upon termination of this License Agreement, you will return these Materials to Honeywellwithout retaining any copies and will have one of your authorized officers certify that all Materials have been

returned with no copies retained.

7. Remedies - Honeywell reserves the right to pursue all available remedies and damages resulting from

a breach of this License Agreement.

8. Limitation of Liability - IN NO EVENT WILL HONEYWELL BE LIABLE FOR ANY INCIDENTALDAMAGES, CONSEQUENTIAL DAMAGES, SPECIAL DAMAGES, INDIRECT DAMAGES, LOSS OFPROFITS, LOSS OF REVENUES, OR LOSS OF USE, EVEN IF INFORMED OF THE POSSIBILITY OF

SUCH DAMAGES. TO THE EXTENT PERMITTED BY APPLICABLE LAW, THESE LIMITATIONS ANDEXCLUSIONS WILL APPLY REGARDLESS OF WHETHER LIABILITY ARISES FROM BREACH OF

CONTRACT, WARRANTY, TORT (INCLUDING BUT NOT LIMITED TO NEGLIGENCE), BY OPERATIONOF LAW, OR OTHERWISE.

9. Controlling Law - This License shall be governed and construed in accordance with the laws of the Stateof New York without regard to the conflicts of laws provisions thereof. This license sets forth the entire

agreement between you and Honeywell and may only be modified by a writing duly executed by the dulyauthorized representatives of the parties.

Copyright - Notice

Copyright 2007 Honeywell International Inc. All rights reserved.XM Radio and XM Satellite are registered trademarks of XM Satellite Radio Inc.

WxWorx is a registered trademark of Baron Services, Inc.IRIDIUM is a registered trademark of IRIDIUM Satellite LLC.


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n KDR 610REVISION HIGHLIGHTS

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KDR 610

Part Number Rev Date Description

006-10714-0000 0 Jan/2007 Initial Release


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Part Number Rev Date Description


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n KDR 610TABLE OF CONTENTS

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2-20

2-20

2.4 POST-INSTALLATION CHECKS.............................................................................2-21

2.4.1 KDR 610 SYSTEM CHECKOUT ............................................................................... 2-21

2.4.1.1 Inspection .................................................................................................................. 2-212.4.1.2 Post-Installation Checkout......................................................................................... 2-22

2.4.1.3 Post-Installation Operation ........................................................................................ 2-23

SECTION 3

OPERATION

3.1 GENERAL ................................................................................................................... 3-1

APPENDIX A

ENVIRONMENTAL QUALIFICATION FORMS


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n KDR 610LIST OF FIGURES

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FIGURE 2-1 P6101 D-SUB CONNECTOR.......................................................................2-7FIGURE 2-2 CONTACTS AND CRIMP, INSERTION, AND EXTRACTION TOOLS........ 2-9FIGURE 2-3 KDR 610 INSTALLATION DRAWING........................................................2-10FIGURE 2-4 KDR 610 INSTALLATION BRACKET DRAWING......................................2-12FIGURE 2-5 KDR 610 END ITEM DRAWING ................................................................ 2-14FIGURE 2-6 ANTENNA OUTLINE AND MOUNTING DRAWING .................................. 2-16

FIGURE 2-7 KDR 610 RECEIVER INTERCONNECT DRAWING..................................2-17FIGURE 2-8 STRAIGHT SMA CONNECTOR ASSEMBLY INSTRUCTIONS................2-19FIGURE 2-9 90 DEGREE SMA CONNECTOR ASSEMBLY INSTRUCTIONS.............. 2-20FIGURE 2-10 LED / DIP SWITCH SETTINGS .................................................................2-23FIGURE 2-11 KMD 540 POWER UP SELF TEST PAGE................................................. 2-24FIGURE 2-12 KMD 540 JEPPESEN DATABASE PAGE ................................................. 2-25FIGURE 2-13 KMD 540 FIS CAUTION PAGE..................................................................2-25FIGURE 2-14 KMD 540 MAP PAGE.................................................................................2-26FIGURE 2-15 XM RADIO ANTENNA AND SIGNAL ICONS.......................................... 2-26FIGURE 2-16 KDR 610 XM RADIO FIS DATA PAGE ...................................................2-27FIGURE 2-17 KDR 610 XM RADIO FIS DATA PAGE (Low Satellite BER) ................... 2-28FIGURE 2-18 KDR 610 XM RADIO FIS DATA PAGE (Low Terrestrial BER)................ 2-29


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n KDR 610LIST OF FIGURES

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TABLE 1-1 TECHNICAL CHARACTERISTICS .............................................................. 1-2TABLE 1-2 SIGNAL OUTPUTS ...................................................................................... 1-2TABLE 1-3 KDR 610 VERSIONS ................................................................................... 1-3TABLE 1-4 DISPLAY UNITS ..........................................................................................1-3TABLE 1-5 KDR 610 INSTALLATION KIT......................................................................1-3TABLE 2-1 CABLE LOSS CHART.................................................................................. 2-5

TABLE 2-2 P6101 PIN FUNCTION LIST........................................................................ 2-7TABLE 2-3 P6102 (ANTIN) / P6103 (ANTOUT) PIN FUNCTION LIST ..........................2-8TABLE 2-4 INSPECTION/CHECK PROCEDURE........................................................ 2-21TABLE 2-5 EXPLANATION OF FIELDS - KDR 610 XM RADIO FIS DATA PAGE ... 2-27


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SECTION 1GENERAL INFORMATION

1.1 INTRODUCTION

This manual describes the physical, mechanical, and electrical characteristics of the

Honeywell Bendix/King KDR 610 XM RadioData Link Receiver. General installationprocedures are also included. Please note that the majority of the examples within thismanual are using the KMD 550/850 display with software version 02/01. For informationregarding any other display, refer to the installation manual for that display.

1.2 EQUIPMENT DESCRIPTION

The KDR 610 receives aviation data directly from the XM Radiosystem in the S-BandSDARS (Satellite Digital Audio Radio System) FCC allocated broadcast band of 2332.5to 2345 MHz centered on 2338.75 MHz.

The XM Radiosystem consists of multiple elements including Baron WxWorx, weatherdata provider; ground based processing and uplink facilities; two equatorial satellites thatare both active providing redundant signals; and subscriber receivers. In addition, the XMRadio satellites are assisted by a ground network of repeater transmitters. Theserepeaters are intended for ground based use in urban area, and are not used by airbornesystems. Receivers must have at least one satellite in view at all times in order to receivethe weather signal without data loss. The satellites appear at approximately a 40 degreeelevation angle in the SSW and SSE sky when viewed from the central United States(Wichita, Kansas).

NOTE: XM Radio

weather information is supplied for strategic flight planning andsituational awareness only. It is not intended for tactical maneuvering purposes.

The KDR 610 has no external controls of its own and broadcasts data only when poweris applied to the unit. The antenna is a top mounted teardrop patch style or a patchcombined with other antenna functions. An internal antenna input splitter inside thereceiver enclosure provides an antenna output that may be used for additional XM Radioreceivers, avoiding the need for an additional antenna.

The KDR 610 XM RadioData Link Receiver is contained in an aluminum enclosure (seeFIGURE 2-3 KDR 610 INSTALLATION DRAWING for physical dimensions and other

installation information. )The unit may be mounted horizontally, or vertically using theoptional mounting bracket (see FIGURE 2-4 KDR 610 INSTALLATION BRACKETDRAWING). The receiver amplifies, demodulates, performs error correction anddetection, decompresses, and formats the data. The receiver operates in a broadcastmode only, no input commands are required for normal operation. The electrical I/O isprovided by a 37 pin D-subminiature connector for the non-RF signals and a SMA coaxialconnector for both the antenna input and output.


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1.3 TECHNICAL CHARACTERISTICS

1.3.1 KDR 610 TECHNICAL CHARACTERISTICS

TABLE 1-1 TECHNICAL CHARACTERISTICS

TABLE 1-2 SIGNAL OUTPUTS

TSO Compliance TSO-C113

Physical Dimensionsincluding weight:

Refer to FIGURE 2-3 KDR 610 INSTALLATION DRAWING.

Mounting: Remote mounted inside pilot/passenger envelope or otherremote mounted location such that the environmentalconditions do not exceed the conditions set forth inAPPENDIX A ENVIRONMENTAL QUALIFICATION FORMS.

CoolingRequirements:

None.

Temperature Range: -55C to +70C.Altitude Range: 55,000 ft. MSL maximum.

Power Inputs: 10 VDC to 32.2 VDC.

Power Supply CurrentRequirements

Maximum currents are:0.6 Amps at 11.0 VDC0.3 Amps at 22.0 VDCNominal input currents and voltages:0.4 Amps at 14 VDC0.2 Amps at 28 VDC

Physical Layer:Serial Protocol:

Serial Data Rate:

RS-422.Asynchronous, No start bit, 2 stop bits, 8 data bits, no parity , nohandshaking.User selectable via DIP switch. Available rates are 19.2, 57.6,115.2 or 125 kbps. The only supported rate for the KMD 540/550/850 is 57.6kbps. See FIGURE 2-10 LED / DIP SWITCH

SETTINGS for DIP setting information.


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1.4 UNITS AND ACCESSORIES SUPPLIED

1.4.1 KDR 610 XM RECEIVER

The KDR 610 is available in the following version:

TABLE 1-3 KDR 610 VERSIONS

1.4.2 DISPLAY UNITS

TABLE 1-4 DISPLAY UNITS

NOTE: When using the KMD 540 as a Weather display, the KMD 540 must contain aKAC 503 card and a Database card with software of 02/01 or later.

1.4.3 KDR 610 INSTALLATION KIT

The KDR 610 Installation Kit (P/N: 4092757-102) for the XM WX Receiver and theXMRANT Antenna contains the following items.I

TABLE 1-5 KDR 610 INSTALLATION KIT

Part Number Version

4092743-902 KDR 610

Display Unit Part Number Bezel

KMD 540 Multi-function Display 066-04035-0101/-1101 Black

KMD 540 Multi-function Display 066-04035-0201/-1201 Gray

KMD 540 Multi-function Display 066-04035-0301/-1301 Silver Crown

ITEM PART NO. DESCRIPTION QTY.

1 CON445 Connector, DB37S, Mil-C-24308/2-4F, with contacts 1

2 CON447 EMI/RFI backshell, DB37 1

3 CON432 SMA Plug, Straight, RG400/142 1

4 CON493 SMA Plug, R/A, RG400/142 1

5 HDW399 Screw, 8-32 X 0.38 FH, MS24693C48 4

6 HDW398 Nut, 8-32, Nylon Lock, MS21083C08 4

7 4092757-10 Optional Receiver Mounting Bracket 1


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1.5 ACCESSORIES REQUIRED, BUT NOT SUPPLIED

1.5.1 ANTENNA

The antenna to be used with the KDR 610 XM Radiodata link receiver must be of the

active amplifier type similar to those used for GPS. The gain of the active antenna mustbe specified in the range of +26 to +34 dB to meet the required signal input levels of thereceiver. The tuned frequency range of the antenna must include the XM RadioSatellitefrequencies of 2332.5 to 2345 MHz.

The recommended antenna types for the XM Radio data link receiver are as follows:

1) Teardrop low profile style, XM Radio reception only - Honeywell P/N4092744-901, or Heads Up Technologies P/N XMRANT-01, or Comant P/NCI 420-1.

2) Combined VHF/ XM Radio style, low speed single engine - Comant CI2480-206.

Either antenna is also capable of XM Radio audio reception, as well as weather. Ifanother antenna type is used, it is the responsibility of the installer to determine suitabilityof the antenna for the specific installation and to obtain any required approvals.

1.6 OPTIONAL ACCESSORIES

1.6.1 ATTENUATOR

1) Heads Up Technologies, P/N CON529-XX.

2) Aeroflex/ Inmet, P/N 9095-SMA-XX.

For both items, "XX" denotes the attenuation values of 03, 04, 06 or 10 dB.

1.7 LICENSE REQUIREMENTS

None.

1.8 CONTINUED AIRWORTHINESS INSTRUCTIONS

1.8.1 EQUIPMENT

The instructions for continued airworthiness given in the TC or STC approvals for this

product supplements or supersedes the instructions for continued airworthiness in thismanual.

Most Honeywell products are designed and manufactured to allow "on conditionmaintenance". On condition maintenance is described as follows; There are no periodicservice requirements necessary to maintain continued airworthiness. No maintenance isrequired until the equipment does not properly perform its intended function. When


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service is required, a complete performance test should be accomplished following anyrepair action. Consult the appropriate unit Maintenance/Overhaul Manual for completeperformance test information.

14 CFR Part 25.1529 Instructions for Continued Airworthiness is met per the followinginstructions:

A. The removal of the equipment is on the condition of failure. There is no re-quired maintenance.

1.8.2 WIRES/COAX CABLES

During on-condition or regularly scheduled maintenance, inspect the wires and coaxcables following the guidelines listed in AC 43.13-1B Chapter 11, 12 as necessary.


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SECTION 2INSTALLATION

2.1 GENERAL INFORMATION

This section contains general suggestions and information to consider before installation

of the KDR 610 XM Radio Data Link Receiver. Close adherence to these suggestionswill assure optimum performance from the equipment.

NOTE: The conditions and test required for the TSO and MOPS approval of this articleare minimum performance standards. It is the responsibility of those installing thisarticle either on or with a specified type or class of aircraft to determine that theaircraft installation conditions are within the TSO and MOPS standards. Thesearticles must have separate approval for installation in an aircraft. Any featuresin this equipment outside the requirements of this applicable TSO and MOPSmust be evaluated and approved as part of the installation approval. The article

may be installed only if further evaluation by the applicant confirms that theinstallation is acceptable and is approved by the Administrator.

2.2 UNPACKING AND INSPECTING EQUIPMENT

Exercise extreme care when unpacking the equipment. Make a visual inspection of theunit for evidence of damage during shipment. If a claim for damage is to be made, savethe shipping container to substantiate the claim. The claim should be promptly filed withthe transportation company. It would be advisable to retain the container and packingmaterial after all equipment has been removed, in the event that equipment storage orreshipment should become necessary.

2.3 EQUIPMENT INSTALLATION

2.3.1 AVIONICS COOLING REQUIREMENTS

None.

2.3.2 EQUIPMENT LOCATION

The following paragraphs contain information pertaining to the initial installation of theKDR 610, including instructions concerning the location and mounting of the supporting

antenna.

The equipment should be installed in the aircraft in a manner consistent with acceptableworkmanship and engineering practices and in accordance with the instructions set forthin this publication. To ensure that the system has been properly and safely installed in theaircraft, the installer should make a thorough visual inspection and conduct an overalloperational check of the system on the ground prior to flight.


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The installation should be in accordance with standards established by the customersinstalling agency and existing conditions as to unit location and type of installation;however, the following should be considered before installing the system in order toassure a more satisfactory performance from the equipment.

NOTE: The TSO identifies the minimum performance standards, tests, and otherconditions applicable for issuance of design and production approval of thearticle. The TSO applicant is responsible for documenting all limitations andconditions suitable for installation of the article. An applicant requesting approvalfor installation of the article within a specific type or class of product is responsiblefor determining environmental and functional compatibility.

Care should be exercised to avoid mounting components near equipment operating withhigh pulse current or high power outputs such as radar and satellite communicationsequipment. In general, the equipment should be installed in a location convenient foroperation, inspection, and maintenance, and in an area consistent with the TSO

environmental limits. Determine the mounting location for system components followingthe guidelines below.

2.3.3 KDR 610 MECHANICAL INSTALLATION

The KDR 610 is a remote LRU and shall be mounted inside the pilot/passenger envelopeor other remote mounted location such that the environmental conditions do not exceedthe conditions set forth in APPENDIX A ENVIRONMENTAL QUALIFICATION FORMS.

The KDR 610 installation will conform to standards designated by the customer, installingagency, and existing conditions as to the unit location and type of installation. Refer to

FIGURE 2-3 KDR 610 INSTALLATION DRAWING for additional KDR 610 installationinformation. Refer to FIGURE 2-4 KDR 610 INSTALLATION BRACKET DRAWING forinformation relating to the optional KDR 610 bracket. Utilizing the bracket supplied theKDR 610 can be mounted in either the vertical plane or the horizontal plane .

NOTE: As part of the KDR 610 mechanical installation, ensure that access to the unitsconnectors, LEDs, and DIP (Dual In-line Package) switches are accessible forpost-installation setup and checkout (see 2.4.1.2 Post-Installation Checkout).

2.3.4 SATELLITE ANTENNA INSTALLATION

2.3.4.1 XM Radio

Antenna Installation Considerations

NOTE: This is applicable to the teardrop low profile style, XM Radio reception onlyantenna (see section 1.5.1 ANTENNA). For all others, refer to themanufacturers information.


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CAUTION: THE SATELLITE ANTENNA IS ELECTROSTATIC DISCHARGE (ESD)SENSITIVE. THE FOLLOWING ESD PROTECTION PROCEDURESMUST BE USED AS A MINIMUM.

1) Do not remove the ESD protective plug from the connector until the coaxialcable is ready to be connected to the antenna.

2) Use a grounded wrist strap when attaching the coaxial cable to the antenna.

3) Ensure that the receiver is not turned on until the antenna and antenna co-axial cable are both completely installed.

4) Ground the center pin of the coaxial cable using two jumper cables beforeconnecting it to the antenna in order to dissipate any residual ESD chargesthat may have accumulated.

The KDR 610 is designed for use with various XM Radiotype-certified antennas coveringthe S-Band from 2.332 GHz to 2.345 GHz. For a list of preferred antennas, refer to section1.5.1 ANTENNA. Due to the low signal levels inherent with satellite communications, the

following guidelines and recommended practices should be adhered to for the design ofthe antenna installation: Install IAW AC 43.13-2A Chapter 3, AC 43.13-1B Chapter 11, the antenna

manufacturer instructions, and in a manner acceptable to the Administrator. Toensure adequate structural strength of the aircraft from associated air loading duringflight, use a backing plate or doubler (not supplied). It is the responsibility of theinstallation agency to determine the appropriate and adequate installation.

Mount the antenna on the top of the aircraft to an external surface such as thefuselage, away from obstructions such as propellers, tail surfaces, or larger antennas,as to not shadow the antenna from line-of-sight reception of the satellites, thusallowing the best possible sky view down to the horizon during all aircraft maneuvers.

Mount antenna as high on the fuselage as practical. Relocation of other lesslocation-sensitive transmitters may be necessary to achieve optimal XM Radioreception performance.

The antenna should be mounted in a location where it is protected from mechanicaldamage during normal flight operations.

The mounting of the antenna must provide an electrical bond of 0.003 ohms or lessthe airframe ground. To eliminate aluminum oxidation on bare metal surfaces, treatthe surface with Alodine 1200 or Irridite.

On top wing aircraft, the antenna should be mounted toward the leading edge of thewing to minimize shading the antenna during climb-out. Avoid mounting the antennaat the rear edge of the windshield since, under certain conditions, static may be

generated in this area. The location selected should provide the least visual line ofsight path from the signal source to the antenna elements.

Painting of the antenna is not recommended and may degrade performance. Modification of the antenna will void the warranty.

2.3.4.2 Interference from VHF and SATCOM Transmitters


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Mount the antenna no closer than 36 inches to VHF-Comm transmitters of 15 Watts

or less. For more powerful transmitting antennas, XM Radio separation should be aminimum of 48 inches. Mount the antenna no closer than three feet from any otherparts of the airframe which could cause detuning of the antenna.

INMARSAT SATCOM antennas transmit at 40 Watts or more and should be separated

by the largest distance possible, or a minimum of 36 inches. IRIDIUM SATCOM antenna separations down to 18 inches are acceptable. Installation pre-testing (see note below) should be performed if the separation is less

than 60-inches. If a XM Radio/VHF-Comm combo style antenna is being installed andreplacing the operation of an existing approved antenna installation, the existingseparations are acceptable.

When routing the antenna cable, the maximum possible separation from transmitterantenna feed cables must be considered, especially with SATCOM and other highpower transmitters. Antenna feed cables of VHF transmitters of 15 Watts or lessshould only require a minimal separation.

Receive only antennas such as ADF and GPS do not produce interference and require

little separation. The XM Radio

antenna should be placed as close as possible tothese types of antennas to gain separation from transmitters.

NOTE: Installation pre-testing is advised if this installation is being performed on severalsimilar aircraft such as a fleet. A pre-test can be performed by mounting theantenna on a piece of aluminum sheet, approximately 24 in diameter or square,to serve as a temporary ground plane. This antenna assembly would then lay onthe aircraft skin near the proposed installation location for an active ground testprior to cutting mounting holes. This has proven both beneficial and cost effectivein past fleet installations since all transmit equipment can be operated and testedfor XM Radio receiver interference prior to the actual installation.

2.3.4.3 Antenna Coaxial Cable Installation Considerations

Refer to TABLE 2-1 CABLE LOSS CHART and FIGURE 2-8 STRAIGHT SMACONNECTOR ASSEMBLY INSTRUCTIONS or FIGURE 2-9 90 DEGREE SMACONNECTOR ASSEMBLY INSTRUCTIONSas required.

The correct cable loss of the antenna feed cable is critical to the performance of thesystem operation. The design configuration of the receivers input is preset to expect atotal antenna and coax system gain of 22dB +6/-4 dB.

Typical XM Radio type-certified aircraft antennas are configured with a total gain of +26to +34 dB where the total cable loss is adjusted to provide the correct antenna and coaxsystem gain to the receiver. Always refer to the antenna specifications to insure thecorrect gain. If desired, additional loss of 0.3 dB for each SMA connector can be addedbut is not crucial to system performance.


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TABLE 2-1 CABLE LOSS CHART below provides reference information for lengths forvarious 50 ohm cable types that are commonly used with SMA connectors to produce theacceptable loss when used with antennas with +26 to +34 dB of gain.

When antennas of other gain values or other cable types are installed, the cable lengthcan be determined using the equations below:

Min. cable length (feet) = {(Max antenna gain - 28) / Cable loss rating (in dB/ 100 ft.)} X 100

Max. cable length (feet) = {(Min antenna gain - 18) / Cable loss rating (in dB/ 100 ft.)} X 100

When the distance between the antenna and receiver is short, run the amount of cablerequired to meet the loss requirement and stow excess length. An alternative to stowinglarge amounts of excess cable is to install a low power RF attenuator in-line with the cable.This system requires a DC bias passing type attenuator that has a frequency rating thatfalls within the maximum satellite frequency of 2.345 GHz. Once acceptable loss

requirements are met, minimizing coax cable length and using gold plated SMA coaxialconnectors will maximize signal strength. For a recommended attenuator, refer to section1.6.1 ATTENUATOR.

2.3.4.4 SATELLITE ANTENNA INSTALLATION

(1) Drill holes in the aircraft skin per the dimensions and notes shown in FIG-URE 2-6 ANTENNA OUTLINE AND MOUNTING DRAWING.

(2) Apply Alumiprep No. 33, to both the inside and outside areas of the fuselageand to the back of the doubler plate. Follow the directions on the containerto cleanse the metal of any left over residue.

(3) Apply Alodine, to both locations following the directions on the container.This is used to ensure good bonding of the antenna and to prevent oxida-tion.

(4) Remove the yellow warning tag from the SMA (F) connector.

(5) Mount the antenna using 4 EA. #8-32 fasteners (not supplied) by sandwich-ing the aircraft skin between the antenna and the internal backing plate.

RG Type (Mil-C-17) Loss Rating (dB/100-Ft.) @ 2.339GHz

142 20.6

400 23.41

TABLE 2-1 CABLE LOSS CHART


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(6) Carefully tighten the hardware so that uniform stress is placed on either sideof the antenna element, ensuring that the connectors have sufficient clear-ance through the aircraft skin.

NOTE: Metal adapter plates are optional; however, they should be used if the curvatureor compound radius of the skin is such that the antenna cannot be directly

installed.

(7) Torque the fasteners to a maximum of 20-25 in-lbs.

CAUTION: DO NOT OVER-TORQUE THE FASTENERS.

(8) Apply a small, smooth fillet of P/S 870 Class B or equivalent sealant aroundthe periphery of the antenna.

NOTE: Do not apply sealant on the fastener heads at the base of the antenna.

(9) By hand, screw on the right angle SMA (M) connector on the coaxial cableto the SMA (F) connector on the antenna.

(10) Torque to 7-10 in-lbs.

CAUTION: DO NOT OVER-TORQUE THE SMA CONNECTOR.

NOTE: For composite aircraft, the addition of a ground plane, as indicated in FAAAdvisory Circular 43.13-2A, section 37.C, may enhance performance. Receiverlightning protection can be improved by grounding the coaxial shield with anappropriate metal mounting clamp placed at a convenient location before thereceiver is connected to the antenna. Other than these considerations, antenna

installation is the same as on a conventional aircraft.

2.3.5 ELECTRICAL INSTALLATION

2.3.5.1 General Information

A. The installing facility will supply and fabricate all external cables. The re-quired connectors are supplied as part of the installation kit (With the excep-tion of the antenna coax connector). Refer to FIGURE 2-7 KDR 610 RE-

CEIVER INTERCONNECT DRAWING.B. The length and routing of the external cables must be carefully planned be-

fore attempting the actual installation. Avoid sharp bends or locating the ca-ble near aircraft control cables. All cables should be well secured to preventcable movement.

C. Do not route the antenna cable near any cable used for a transmitting an-tenna. In a reciprocating aircraft, do not route the cable near the magnetoP-leads or high tension ignition leads.


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Prior to installing the KDR 610 itself, a point to point continuity check of thewiring harness should be done to verify proper wiring. The aircraft power in-put to the unit should be made to insure that power is applied to only thespecified power pin(s).

2.3.5.2 Functional Pinout Descriptions

This section gives a brief description of the inputs and outputs of the KDR 610 Receiver.It is provided so the installer can determine what specific wiring needs to be done to theaircraft in which the KDR 610 is to be installed. Unless otherwise specified, pins not used,i.e. marked N/C, are to be left open.

FIGURE 2-1 P6101 D-SUB CONNECTOR

Pin # I/O Function Pin # I/O Function

1 N/C 20 N/C

2 N/C 21 N/C

3 N/C 22 N/C

4 N/C 23 N/C

5 N/C 24 N/C

6 N/C 25 N/C

7 N/C 26 N/C

8 N/C 27 N/C

9 N/C 28 N/C

10 N/C 29 N/C

11 N/C 30 N/C

12 N/C 31 N/C

13 N/C 32 N/C

14 N/C 33 O 422TXL

15 O 422TXH 34 N/C

16 N/C 35 N/C

17 N/C 36 N/C

18 I 28VDC ENABLE 37 GND

19 I 28 VDC INPUT

TABLE 2-2 P6101 PIN FUNCTION LIST


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TABLE 2-3 P6102 (ANTIN) / P6103 (ANTOUT) PIN FUNCTION LIST

2.3.5.3 Crimp Tool Information

Note: Contacts (sockets): M39029/63-368 (included with CON445).

Note: Tools and positioners from ASTRO and DANIELS are interchangeable.

SMA connectors utilize Tyco crimp tool PN 354940-1and crimp die 91908-1

Vendor Ordering Information:

Astro Tool Company21615 SW TV Hwy, Beaverton, OR 97006(503) 642-9853 * Fax: 503-591-7766 * Email: [email protected]

Daniels Manufacturing Company (DMC)526 Thorpe Road, Orlando, FL 32824-8133 USATel: 407-855-6161 * Fax: 407-855-6884 * Email: [email protected]

Desoto International Inc.

5454 San Fernando Rd

Glendale, CA 91203

Positronics Industries, Inc.423 N. Campbell Ave P.O. Box 8247, Springfield, MO 65801Tel: 800-641-4054 * Fax: 417-866-4115 * Email: [email protected]

Pin # I/O Function P6102 Pin # I/O Function P6103

1 I ANTENNA IN (SMA CONNECTOR) 1 O ANTENNA OUT (SMA CONNECTOR)

MANUFACTURER/SOURCE CRIMP TOOL POSITIONER 18 AWG POSITIONER 20-30 AWG

HONEYWELL 005-02012-0034 N.A. N.A.

MIL-SPEC M22520/2-01 N.A. M22520/2-08

DANIELS MFG. AFM8 (M22520/2-01) K774 K13-1 (M22520/2-08)

POSITRONICS 9507-0-0 9502-11 (K774) 9502-5 (K13-1)

ASTRO (BUCHANAN) 615717 (M22520/2-01) N.A. 615724 (M22520/2-08)

MANUFACTURER/SOURCE INSERTION/EXTRACTION TOOL PART NUMBER

HONEYWELL 005-02012-0025

MIL SPEC M81969/1-02 (SUPERCEDES MIL SPEC P/N: M24308/18-2)ORDER FROM POSITRONICS, DANIELS, OR ASTRO BY MIL SPEC P/N.


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Heads Up Technologies, Inc.2033 Chennault, Ste 100Carrollton, TX 75006Phone: (972) 980-4890 / (800) 367-4770 (US Only)Fax: (972) 980-4843

Comant, Inc.577 Burning Tree RoadFullerton, California 92833714-870-2420(v)[email protected]

Tyco Electronics Corporation

HArrisburg, PA 1-800-722-111

FIGURE 2-2 CONTACTS AND CRIMP, INSERTION, AND EXTRACTION TOOLS


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FIGURE 2-3 KDR 610 INSTALLATION DRAWING(Dwg. XMD157 Rev. -, Sheet 1 of 1)


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FIGURE 2-4 KDR 610 INSTALLATION BRACKET DRAWING(Dwg No XMD157-002 Rev. -)


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FIGURE 2-6 ANTENNA OUTLINE AND MOUNTING DRAWING(Honeywell P/N 4092744-901 (Heads Up Technologies P/N XMRANT-01 Comant P/N CI 420-1))


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FIGURE 2-7 KDR 610 RECEIVER INTERCONNECT DRAWING(Dwg No 155-01811-0000, Rev. -)


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FIGURE 2-8 STRAIGHT SMA CONNECTOR ASSEMBLY INSTRUCTIONSCON432


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FIGURE 2-9 90 DEGREE SMA CONNECTOR ASSEMBLY INSTRUCTIONSCON493


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2.4 POST-INSTALLATION CHECKS

2.4.1 KDR 610 SYSTEM CHECKOUT

The post-installation test is used to apply power and functionally checkout the system.Successful completion of the post-installation test verifies the proper operation of the KDR610.

TABLE 2-4 INSPECTION/CHECK PROCEDURE is a visual inspection/check procedurethat should be performed after system installation as part of a system checkout. Apost-installation test per paragraph 2.4.1.2 Post-Installation Checkout should beperformed. In addition, the procedure should be used as a periodic maintenanceinspection check.

TABLE 2-4 INSPECTION/CHECK PROCEDURE

2.4.1.1 Inspection

Perform the following inspection on the overall system:

(1) Check that cables do not interfere with aircraft controls or other equipment.

(2) Check cabling for proper routing and check security of tie-down points. In-spect and adjust cable runs to ensure that cables are not strained, kinked,or severely twisted and are not exposed to rough or sharp surfaces.

EQUIPMENT INSPECTION/CHECK PROCEDURE

KDR 610 A. Inspect external surface for damage.

B. Ensure that the unit is securely installed.

C. Ensure that all connections to the mounting tray are properlymounted and secure (if used).

D. Ensure that the DB 37 power and data connector (P6101) issecure and that retention screws are tightened.

Antennas A. Inspect external surfaces for damage.

B. Check that antenna is properly mounted and secure.

C. Ensure that antenna coaxial cable connectors are properlymated and tightened to 7-10 inch pounds of applied torque.


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2.4.1.2 Post-Installation Checkout

(1) General

Installation of the KDR 610 system requires the following stages of testingto ensure the proper operation. Initially, prior to the installation of the KDR

610 and antenna, a system interwiring check should be performed. Thischeck verifies that the aircraft and all KDR 610 interconnections are correctbefore power is applied. After the units are installed a visual inspection ofthe equipment and connections is made.

(2) System Interwiring Check

To check the aircraft and KDR 610 system interconnections proceed as fol-lows:

(a) Check that all cables and interwiring are installed in accordance withthe Interwiring and Cable Harness Fabrication instructions (para-graph 2.3.5 ELECTRICAL INSTALLATION).

(b) Using the applicable interconnection information, check wiring forproper destination, opens, and shorts.

(c) Check RF cables for insertion loss and VSWR.

(3) Receiver Checkout

For receiver checkout verification, refer to FIGURE 2-10 LED / DIP SWITCHSETTINGS as required.

(a) Verify that the upper DIP switches (Ref. D) are all set to the down po-sition.

(b) Verify that the lower DIP switches are as shown, from left to right, thefirst six switches in the down position and the two right-most switches

in the up position, thus setting the serial data rate to 57.6 kbps. If theswitches are not in the positions as described, place them in the cor-rect position.

(c) Apply 14 / 28VDC power.

(d) After reset is complete (indicator LEDs remain on), verify the powerLED (Ref A) is illuminated and red in color.

(e) Verify the amber LEDs (Ref B and C) are illuminated and amber incolor.

(f) Receiver should be operative at this point.


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FIGURE 2-10 LED / DIP SWITCH SETTINGS

2.4.1.3 Post-Installation Operation

The following procedures will verify that the KDR 610 is functioning properly.

NOTE: For KMD 540 XM Radiooperation, ensure that the KAC 503 FIS Module hasbeen properly installed in the KMD 540 MFD and that the KMD 540 has beenconfigured for XM RadioFIS weather. Refer to the KMD 550/850 InstallationManual (P/N 006-10608-00XX) as required for FIS installation and configuration.

NOTE: The system requires XM WX subscription service activation from XM SatelliteRadio Inc. For installation purposes only, a temporary XM WX Satellite Weatherservice is preactivated from the factory. This activation will terminate

automatically without prior notice. To avoid unexpected deactivation,customers should contact XM Satellite Radio Inc. at 1-800-985-9200 totransfer the subscription immediately after installation. Refer to the KMD550/850 Installation Manual (P/N 006-10608-00XX) as required for XMinstallation and configuration.

NOTE: Version 02/01 software update/ database card must be installed in the KMD 540to support satellite receiver operation.


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NOTE: During post-installation operation, an unobstructed view of the southern sky or aterrestrial repeater is required in order to receive the weather signal.

NOTE: The post-installation information presented here is based on the KMD 540 unit.For other systems, refer to the applicable installation manual.

(1) Power on the KMD 540 by turning the On/Off Control, located in the lowerleft corner, clockwise. During power up, a sequence of pages will appear.

(a) First is the title (splash) page with the Bendix/King logo (not shown).

(b) Next is the self-test page (similar to FIGURE 2-11 KMD 540 POWERUP SELF TEST PAGE). If no errors occur during self test, the sys-tem will automatically advance to the next page. If errors occur, thePower Key to the right of the OK Soft Label must be pressed to con-tinue.

(c) This page also displays the option modules that have been installedin the unit. Ensure that FIS INTERFACE is displayed with a green

check mark next to it.

FIGURE 2-11 KMD 540 POWER UP SELF TEST PAGE

(2) The next page of the sequence is the Jeppesen Database Acknowledge-ment page (see FIGURE 2-12 KMD 540 JEPPESEN DATABASE PAGE).

To continue, press the Power Key to the right of the OK Soft Label.


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FIGURE 2-14 KMD 540 MAP PAGE

To verify that the KDR 610 is functioning properly, monitor the antenna iconin the lower left of the Map screen

(a) Verify that there is an antenna icon without a red slash.

(b) Verify that there are signal strength bar(s) to the right of the antennaicon.

1. The presence of the signal strength bars verifies signal withthe KDR 610 receiver and the strength of the signal.

2. The lack of signal strength bars indicates no signal.

3. The red slash through the antenna icon indicates a fault withthe connection or data link receiver

See FIGURE 2-15 XM RADIO ANTENNA AND SIGNAL ICONSforadditional information.

FIGURE 2-15 XM RADIO ANTENNA AND SIGNAL ICONS


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(5) KDR 610 BER Conditions

FIGURE 2-16 KDR 610 XM RADIO FIS DATA PAGE is used to view de-tails of the data being received from the XM RadioSatellite system via theKDR 610. This page shows nominal conditions in terms of satellite and ter-restrial Bit Error Rate (BER) status.

This page may be accessed using the AUX function key. Refer to instruc-tions in the KMD 550/850 Installation Manual (P/N 006-10608-00XX) as re-quired in order to access this screen. An explanation of the various fieldsshown on the FIS data page is shown in TABLE 2-5 EXPLANATION OFFIELDS - KDR 610 XM RADIO FIS DATA PAGE.

FIGURE 2-16 KDR 610 XM RADIO FIS DATA PAGE

Field Explanation

System Time Current time in MM/DD/YY HH:MM:SS (24 hour UTC time). This field will bedashed if time is not available.

Link errors Number of Link layer frames that contained errors (first value) of the total

number of valid frames received (second value) from the weather receiver.

CRC errors Number of data product packets received that contained CRC errors (first

value) of the total number of data product packets received (second value)from the weather receiver.

Satellite #1 BER Bit Error Rate (BER) detected by the receiver for satellite #1 - displayed as

a percentage (0 to 100) if known and '-' if unknown.

Satellite #2 BER Bit Error Rate (BER) detected by the receiver for satellite #2 - displayed asa percentage (0 to 100) if known and '-' if unknown.

TABLE 2-5 EXPLANATION OF FIELDS - KDR 610 XM RADIO FIS DATA PAGE


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FIGURE 2-17 KDR 610 XM RADIO FIS DATA PAGE (Low Satellite BER)shows reception of two satellites with low BER. FIGURE 2-18 KDR 610 XMRADIO FIS DATA PAGE (Low Terrestrial BER) show reception of a near-by terrestrial repeater with low BER. Either of these conditions can occur de-pendent upon the aircraft position relative to ground based repeaters, andeither indicate normal operation. If the BER indication is high, i.e., more than10 for both satellite and terrestrial sources, there is a problem with the an-tenna, transmission line, or receiver.}

FIGURE 2-17 KDR 610 XM RADIO FIS DATA PAGE (Low Satellite BER)

Terrestrial BER Bit Error Rate (BER) detected by the receiver for the terrestrial transmitter -displayed as percentage (0 to 100) if known and '-' if unknown.

Last product ID Displays the identifier of most recently received product:001 NEXRAD

005 METAR027 AIRMET

028 SIGMET042 TAF

Last image time Creation Time of last received NEXRAD image in MM/DD/YY HH:MM:SS (24hour UTC time).

Field Explanation

TABLE 2-5 EXPLANATION OF FIELDS - KDR 610 XM RADIO FIS DATA PAGE


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g

FIGURE 2-18 KDR 610 XM RADIO FIS DATA PAGE (Low Terrestrial BER)


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