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INSTALLATION MANUAL
190-00231-00, Revision E
February 2005
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© Copyright 2002-2005
Garmin Ltd. or its Subsidiaries
All Rights Reserved
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, disseminated,
downloaded or stored in any storage medium, for any purpose without the express prior written consent of Garmin.
Garmin hereby grants permission to download a single copy of this manual and of any revision to this manual onto a
hard drive or other electronic storage medium to be viewed and to print one copy of this manual or of any revision
hereto, provided that such electronic or printed copy of this manual or revision must contain the complete text of this
copyright notice and provided further that any unauthorized commercial distribution of this manual or any revision
hereto is strictly prohibited.
Information in this document is subject to change without notice. Garmin reserves the right to change or improve its
products and to make changes in the content without obligation to notify any person or organization of such
changes or improvements.
Garmin is a registered trademark and GDL is a trademark of Garmin Ltd. or its subsidiaries and may not be used
without the express permission of Garmin.
RECORD OF REVISIONS
Revision
Revision Description ECO #
Date
A 5/31/02 Production Release 18266
B 9/19/02 Add PMA/STC info, other misc. changes 19063
C 4/17/03 Update power/Tx specs, other misc. changes 20822
D 5/19/03 Replaced copy of STC w/ amended version. 21128
E 2/17/05 Removed reference to rubber gasket 29800
DOCUMENT PAGINATION
This document may contain information which is subject to the Export Administration Regulations
(“EAR”) issued by the United States Department of Commerce (15 CFR, Chapter VII, Subchapter C)
and which may not be exported, released, or disclosed to foreign nationals inside or outside of the United
States without first obtaining an export license. A violation of the EAR may be subject to a penalty of up
to 10 years imprisonment and a fine of up to $1,000,000 under Section 2410 of the Export Administration
Act of 1979. Include this notice with any reproduced portion of this document.
WARNING
This product, its packaging, and its components contain chemicals known to the State of
California to cause cancer, birth defects, or reproductive harm. This Notice is being
provided in accordance with California's Proposition 65. If you have any questions or
would like additional information, please refer to our web site at www.garmin.com/prop65.
The following table identifies hardware modification (Mod) Levels for the GDL 49 data link
transceiver. Mod Levels are listed with the associated service bulletin number, service bulletin date, and
the purpose of the modification. The table is current at the time of publication of this manual (see date on
front cover) and is subject to change without notice. Authorized Garmin Sales and Service Centers are
encouraged to access the most up-to-date bulletin and advisory information on the Garmin Dealer
Resource web site at www.garmin.com using their Garmin-provided user name and password.
SERVICE SERVICE
MOD
BULLETIN BULLETIN PURPOSE OF MODIFICATION
LEVEL
NUMBER DATE
1. GENERAL DESCRIPTION
1.1 INTRODUCTION..............................................................................................................1-1
1.2 EQUIPMENT DESCRIPTION...........................................................................................1-1
1.3 TECHNICAL SPECIFICATIONS......................................................................................1-2
1.4 CERTIFICATION..............................................................................................................1-3
1.5 LICENSE REQUIREMENTS .............................................................................................1-3
1.6 LIMITED WARRANTY ....................................................................................................1-4
2. INSTALLATION
2.1 INTRODUCTION..............................................................................................................2-1
2.2 EQUIPMENT LOCATION CONSIDERATIONS...............................................................2-1
2.3 CABLING AND WIRING..................................................................................................2-1
2.4 VHF ANTENNA CONSIDERATIONS..............................................................................2-2
2.5 ANTENNA INSTALLATION PROCEDURES .................................................................2-5
2.6 ANTENNA INSTALLATION APPROVAL .....................................................................2-6
2.7 CONTINUED AIRWORTHINESS.....................................................................................2-6
2.8 COAXIAL CABLE INSTALLATION................................................................................2-7
3. INSTALLATION PROCEDURE
3.1 UNIT AND ACCESSORIES ..............................................................................................3-1
3.2 MISCELLANEOUS OPTIONS..........................................................................................3-1
3.3 INSTALLATION ACCESSORIES REQUIRED BUT NOT PROVIDED............................3-1
3.4 CABLE INSTALLATION..................................................................................................3-2
3.5 UNIT INSTALLATION.....................................................................................................3-2
3.6 UNIT OUTLINE DRAWING.............................................................................................3-3
3.7 UNIT INSTALLATION DRAWING..................................................................................3-4
3.8 ANTENNA INSTALLATION DRAWING.........................................................................3-6
4. SYSTEM INTERCONNECTS
4.1 PIN FUNCTION LIST-J491 ...............................................................................................4-1
4.2 ANTENNAS......................................................................................................................4-2
4.3 GDL 49 INTERFACE DIAGRAM......................................................................................4-3
5. POST INSTALLATION CONFIGURATION & CHECKOUT PROCEDURE
5.1 INSTALLTION POWER CHECK......................................................................................5-1
5.2 CONFIGURATION MODE OPERATIONS.......................................................................5-1
5.3 ECHO FLIGHT SERVICE ACTIVATION/ESTABLISHING THE DATA LINK................5-1
5.4 SYSTEM OPERATIONAL CHECKOUT...........................................................................5-2
5.5 TROUBLESHOOTING A FAULTY RS-232 LINK ............................................................5-6
APPENDIX A. CERTIFICATION DOCUMENTS
A.1 CONTINUED AIRWORTHINESS....................................................................................A-1
A.2 ENVIRONMENTAL QUALIFICATION FORM...............................................................A-4
APPENDIX B.
B.1 STC PERMISSION ...........................................................................................................B-1
B.2 PMA APPROVAL............................................................................................................B-1
NOTE
Upon completion of the installation and account setup, the installation technician will be able to perform an
end-to-end test of the system. This can be performed by requesting and receiving data, NEXRAD or
METAR. If an account has not been setup, complete testing of the system cannot be performed.
1.2. EQUIPMENT DESCRIPTION
The GDL 49 is a remote-mounted Satellite Data Link Transceiver that provides a means for data to be
communicated between a Garmin 400 or 500 Series unit and an Echo Flight Message Switch. The actual
link being used for transmission and reception over the airwaves is the ORBCOMM low earth orbit (LEO)
satellite constellation. The GDL 49 communicates via RS-232 with a 400/500 Series product and through
VHF communications with the ORBCOMM satellite constellation.
Mode J491 Pins 1 and 2 J491 Pin 10* Total Combined Current
(Warm-up Power)
Rx 0.20 A 1.10 A 1.30 A
Tx 0.90 A 1.10 A 2.00 A
Mode J491 Pins 1 and 2 J491 Pin 25* Total Combined Current
(Warm-up Power)
Rx 0.55 A 2.22 A 2.77 A
Tx 1.80 A 2.22 A 4.02 A
*Please refer to notes 4, 5, and 6 in Figure 4-2 on page 4-3 for specific information on wiring the unit and
warm-up circuit to aircraft power.
Down-Link (RX)
Frequency 137 to 138 MHz, 399 channels (15 Used)
Modulation SDPSK 4800 bits per second
Up-Link (TX)
Output Power ≥5 Watts (37 dBm)
Frequency 148 to 150 MHz, 819 channels
Modulation SDPSK 2400 bits per second
1.4 CERTIFICATION
The GDL 49 initial certification was accomplished via STC by Garmin in a Beech Model 58. See
Appendix B for a copy of the STC, and the PMA number for the GDL 49.
This Garmin product is warranted to be free from defects in materials or workmanship for two year from
the date of purchase. Within this period, Garmin will at its sole option, repair or replace any components
that fail in normal use. Such repairs or replacement will be made at no charge to the customer for parts or
labor, provided that the customer shall be responsible for any transportation cost. This warranty does not
cover failures due to abuse, misuse, accident or unauthorized alteration or repairs.
THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE EXCLUSIVE AND IN LIEU
OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED OR STATUTORY, INCLUDING ANY
LIABILITY ARISING UNDER ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE, STATUTORY OR OTHERWISE. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, WHICH MAY VARY FROM STATE TO STATE.
Garmin retains the exclusive right to repair or replace the unit or software or offer a full refund of the
purchase price at its sole discretion. SUCH REMEDY SHALL BE YOUR SOLE AND EXCLUSIVE
REMEDY FOR ANY BREACH OF WARRANTY.
To obtain warranty service, contact your local Garmin Authorized Service Center. For assistance in
locating a Service Center near you, call Garmin Customer Service at one of the numbers shown below.
Products sold through online auctions are not eligible for rebates or other special offers from Garmin.
Online auction confirmations are not accepted for warranty verification. To obtain warranty service, an
original or copy of the sales receipt from the original retailer is required. Garmin will not replace missing
components from any package purchased through an online auction.
NOTE
Improperly grounded electrical devices, and electrical equipment with switching power
supplies, can generate harmful interference to GDL 49 operation and other equipment.
The GDL 49 communicates with the satellite system on a VHF frequency range that is
susceptible to this RFI interference. There have been cases where RFI in the 135 to 140
MHz range has interfered with GDL 49 reception.
Ensure that all electrical/electronic equipment installed on the aircraft has been properly grounded, and
antenna shields properly terminated at each end of the coaxial runs if you are experiencing any degraded
performance with the GDL 49 or any other system.
2.3 CABLING AND WIRING
Check that there is ample space for the cabling and mating connectors. Avoid sharp bends in cabling, and
routing near aircraft control cables. Cabling for the GDL 49 should not be routed near components or
cabling which are sources of electrical noise. Ensure that the cabling, wire harness and coaxial cable, is
properly secured throughout its end to end run to avoid stress and damage.
When the AV-14 antenna is used in conjunction with the ORBCOMM satellite system, it provides two-
way communication with the satellites requesting and replying with bursts of compressed data. This
section of the Installation Manual is supplementary to R.A. Miller document number 27-1651-4B.
NOTE
Depending on specific installations, the installer may want to use a different make/model
of VHF antenna. There are a variety of antennas that will work with the GDL 49. It is
the installer’s responsibility to ensure that their choice of antenna meets FAA
certification standards according to the specific installation. Please refer to the table
in section 1.3.4 for general guidelines on antenna selection. This installation manual uses
only the AV-14, which was the only antenna used during STC certification by Garmin.
Antenna installations on pressurized cabin aircraft also require FAA approved installation. Design and
engineering substantiation data is needed whenever such antenna installations incorporate alteration
(penetration) of the cabin pressure vessel by connector holes and/or mounting arrangements. For needed
engineering support pertaining to the design and approval of such pressurized aircraft antenna installations,
it is recommended that the installer proceed according to any of the following listed alternatives:
1. Obtain approved antenna installation design data from the aircraft manufacturer.
2. Obtain a FAA approved STC pertaining to and valid for the antenna installation.
3. Contact the FAA Aircraft Certification Office in the appropriate Region and request identification
of FAA Designated Engineering Representatives (DERs) who are authorized to prepare and
approve the required antenna installation engineering data.
4. Obtain FAA Advisory Circular AC-183C and identify a DER from the roster of individuals in it.
5. Contact an aviation industry organization such as the Aircraft Electronics Association for
assistance.
There are several critical factors to take into consideration before installing the AV-14 Antenna in order to
satisfy the needs for satellite communications systems. These factors are now addressed:
NOTE
Improper grounding of the antenna is the primary cause of reduced ability to link with the
ORBCOMM constellation.
If you are installing the antenna over a contoured surface, use a tapered metal shim to prevent
deformation of the aircraft skin or breakage of the antenna base. The structure of the aircraft must be
considered to determine the need for a stiffener. The stiffener should tie into existing structure, or at the
very least, spread the stress out far enough that the stress points are dissipated gradually into the
surrounding airframe skin. Aviation grade mounting screws of the proper grip length must be used for the
application. Torque should be evenly applied across all mounting screws to avoid deformation of the
mounting point.
The ground plane for most aircraft is its aluminum skin. For those aircraft with fabric or composite skin,
using a whip antenna, a ground plane must be constructed. It is usually installed under the skin of the
aircraft, below the antenna, and is made either of aluminum sheet or of a wire mesh. This ground plane
should, at least, have a radius that is as great as the antenna is long.
NOTE
It is very important to have good conductivity between the coaxial shield and the ground
plane. This is ensured by proper antenna installation, where all the fasteners properly
ground the antenna base to the skin of the aircraft. Additionally, by burnishing the
through-holes of the GDL 49 and the attach points on the mounting tray, proper electrical
grounding will be achieved. The resistance between the antenna and the skin of the
aircraft should be less than 10 milliohms.
Location is one of the more critical points in satisfying the needs for satellite communications systems.
This is especially true of the AV-14 antenna used in conjunction with the ORBCOMM system. Metal
members, such as landing gear, struts and tail surfaces can alter the directional pattern of the antenna.
This will cause the antenna to work better in some directions and poorer in others. The AV-14 is to be
mounted on the top of the fuselage (Figure 2-1) in the vertical plane to allow the GDL 49 to communicate
with the satellite system.
As with any COM antenna installation, keep the following points in mind:
1. Locating antennas too close to obstructions such as the vertical stabilizer will limit the radiation pattern
of the transmission, causing nulls and reducing the effective range.
2. Maintain about three feet from heater ignition, autopilot and other control surface actuators and
motors.
Location of non-communication antennas too close to the AV-14 antenna may not only degrade the
transmission through reflection, but can also absorb and re-radiate the transmission causing a condition
similar to having two COM antennas located in close proximity to each other.
• Keep Coaxial runs as short as functionally possible. Greater the length, greater the loss.
• Choose the correct coax: RG-400/U has a good trade off between loss, size, and flexibility.
1. Locate mounting position on top of the fuselage. A good electrical connection must exist
between the mounting fasteners and the metallic frame or skin of the aircraft.
2. Aircraft with non-metallic outer surface should be provided with a ground plane of at least 24”
x 24”. This may be a thin metal sheet on the outside, or immediately under the surface on the
inside. Metal foil, securely connected in place, may be used on the inside surface. The ground
plane must extend under the vertical portion of the antenna. The larger the ground plane the
better the antenna propagation will be.
CAUTION
Any ground plane installed must be well bonded electrically to the metal
frame of the aircraft to prevent erratic electrical noise in the receiver.
3. Using the template shown in the R.A. Miller Installation Instructions, or other as required, drill
four (4) mounting holes and one (1) hole for the connector; note difference between front and
rear of template.
4. Burnish the area around the holes on the interior side of the aircraft. Alodine the exposed
aluminum surface and mount the antenna within one hour. The alodine coating will become
brittle if mounting is delayed beyond one hour.
NOTE
CAUTION
Tighten all mounting screws evenly, using the same torque value, to
insure that the antenna lays flat on the mounting surface.
6. A section of RG-400/U or similar 50-ohm coax cable must run between the antenna and the
GDL 49 transceiver. Both ends are to be equipped with a type BNC (RG-400/U) connector to
connect to the antenna and the GDL 49. The cable and connectors are not supplied but may be
obtained from an electronics parts distributor.
7. Review section 2.8 for steps on how to install the coaxial cable from the antenna to the GDL
49. Refer to section 4.2.1 of this manual for antenna/coax cable checkout.
The conditions and tests required for TSO approval of the AV-14 antenna are minimum performance
standards. It is the responsibility of those desiring to install this antenna on a specific type or class of
aircraft to determine that the installation is within the TSO standards. The AV-14 antenna may be
installed only if further evaluation by the applicant documents an acceptable installation and is approved by
the administrator. For antenna TSO compliance, antenna specifications are as follows:
Application: Communications
Frequency: 138-174 MHz
VSWR: 2.0 to 1 Maximum
Impedance: 50 Ω
Polarization: Vertical
Pattern: Omni-directional
Connector: Type BNC Female
Weight: 8 oz
RF Power Capability: 25 Watts
Height: 18-3/4”
TSO: C37d, C38d, DO-160c
Speed Range: 250 knots
Env.Cat. D2-AC
SXSXDFSXXXXXXXXXX
For a translation of the code categories and applicable specifications, refer to the current copyrighted
RTCA/DO-160( ) document.
Maintenance of the AV-14 antenna is “on condition” only. Periodic maintenance of the AV-14 is not
required.
1. With the GDL 49 transceiver (see Section 3.5), and AV-14 antenna (see Section 2.5) installed
route and clamp the coaxial cable in position (RG-400/U or similar 50-ohm). Secure the cable
in accordance with good aviation practice.
2. Trim the coaxial cable to the desired length and install the BNC connectors
(330-00087-00) at each end per the cabling instructions listed in Figure 2-2. For convenience
one end of the coaxial run can be terminated prior to installation.
NOTE
The 400/500 Series Garmin Optional Displays (P/N 190-00140-13) supercedes the
previous Weather Data Link Pilot’s Guide (P/N 190-00231-05) as the legitimate document
for the GDL-49’s control and operation in conjunction with the 400/500 series units.
Contacts for the 25-pin connector must be crimped onto the individual wires of the aircraft wiring harness.
Tables 3-1 and 3-2 list contact part numbers (for reference) and recommended crimp tools. Refer to
Table 4-1 for J491 pin definitions. Construct the wire harness according to the information listed in Table
4-1 and Figure 4-2. Cable lengths will vary depending upon installation. Route and secure the cable run
from the GDL 49 to the 400/500 Series unit away from sources of electrical noise. Annotate, for later
reference, on the wiring diagram the RS-232 channel that termination to the 400/500 Series unit was
made.
NOTES
1. Insertion/extraction tools from ITT Cannon are all plastic; others are plastic with metal tip.
2. Non-Garmin part numbers shown are not maintained by Garmin and consequently are subject to
change without notice.
Ensure that the installation location is away from sources of electrical noise and provides easy access for
cable and coax routing and connection. Do not close the area as final testing and troubleshooting will
require access to the GDL 49.
Page 3-2 GDL 49 INSTALLATION MANUAL
Rev. E P/N 190-00231-00
3.6 UNIT OUTLINE DRAWING
MOUNTING SHELF
GDL 49
#8 SCREW, WASHER
& NUTPLATE (6 PLCS) J491
MATCHDRILL STRINGERS
#8 SCREW, WASHER
& NUT (6 PLCS)
14 15 16 17 18 19 20 21 22 23 24 25
1 2 3 4 5 6 7 8 9 10 11 12 13
Figure 4-1. View of J491 Connector looking at the back of the GDL 49
Table 4-1. J491 Pin Definitions
The J492 15 Pin Subminiature D connector is reserved for future use (no connection).
4.2 ANTENNAS
Perform the following confidence check of the antenna and coax installation.
1. Gain access to the GDL 49 and remove the antenna BNC connector from the unit.
2. Using an ohmmeter, measure from the shield ground to an airframe ground. It should indicate a short to
ground at this point.
To change data on the displayed Configuration Page, press the small right knob (CRSR) to turn on the
cursor. Turn the large right knob to change between data fields. Turn the small right knob to change a
field that the cursor is on. Select the channel that the GDL 49 was wired to and select GDL 49 in both the
INPUT and OUTPUT locations of that channel (refer to the annotation you made on the wiring diagram
during harness buildup). Once you have made the desired selection, press the ENTER key to accept the
entry. Turn the 400/500 Series off, then on, to place it back into normal operation mode.
NOTE
Use of an external power cart is optional in order to prevent the battery from discharging
to a critically low level.
Power on all systems and allow two to four minutes for initialization. Verify that the 400/500 Series unit is
properly operating and receiving satellite signals and ensure the circuit breaker for the GDL 49 is closed.
To select the Data Link Page, rotate the large right knob until
a page from the AUX group is displayed. To select the Data
Link Page, rotate the small right knob until the Data Link Page Figure 5-2. Data Link Page
is displayed, (Figure 5-2).
5.4.2 Data Link Status
From the Data Link page, select “DATA LINK STATUS”,
Figure 5-3. The Data Link Status page will appear on the
display providing an indication of the operational condition of
the Weather Data system. Six fields, described below, define
the condition of the system.
TX QUEUE
This field shows the number of requests in the GDL 49’s
transmit queue waiting to be sent to the satellite system. None
will be present on the initial installation.
MESSAGE CAUSE
“Data link has failed” There is an internal disconnect in the GDL
49.
“Searching...” No satellite is currently in view.
“Satellite in view” Found satellite but have not yet identified
it.
“Linked to sat” Can exchange data with the satellite.
“_ _ _” RS-232 communication with the
GDL 49 has been lost, or unknown
connectivity status received from the GDL
49.
SATCOM OPERATION
This field indicates the current activity being performed by the satellite communicator within the GDL 49.
The following are possible messages that can be displayed, including interpretations of the most common
ones:
MESSAGE CAUSE
“Idle” Waiting to perform the next task.
“Sending message” Transmitting a message to the
satellite.
“Sending request” Transmitting a request to the satellite.
“Receiving message” Receiving a response from the
satellite.
“_ _ _” Unknown task is being performed, or
RS-232 communication with the GDL
49 has been lost.
Installed within the GDL 49 unit itself is a device known as a Subscriber Communicator. This is the VHF
transceiver that receives and transmits data to the satellite system. Garmin provides this serial number to
Echo Flight during the manufacturing process and is therefore not listed on the GDL 49 unit. Should you
ever need the SC serial number it has been placed here for reference.
GDL SW
This number represents the software load the unit is currently operating under.
On the Data Link Status page note the display for the SAT ID/CONNECTIVITY. It should display a
number for the satellite that is being received and the statement “Linked to sat”. There should be no RX
or TX messages in the queue, and the SATCOM OPERATION field should be “Idle”.
Go to the Data Link page, follow the steps given in section 5.4.1.
1. From the Data Link page select “Metar Request”. To Figure 5-4
highlight Metar Request, press the center of the lower right Data Link Page – Metar
knob, (this turns on the cursor). Turn the small knob until Request
Metar Request is highlighted as shown in Figure 5-4. Press
the ENT key to accept the selection. This takes you to the
METAR REQUEST page.
Figure 5-6
WAYPOINT INFORMATION
This end-to-end test confirms that the installation is proper and the
system is operating correctly.
The above block diagram may be useful to troubleshoot the Data Link system. If the equipment in the
aircraft is working properly but no weather data is being received call Echo Flight to insure service has
been established and their system is in operation.
Aviation Authority approved installers are hereby granted permission to reference appropriate service
instructions and excerpts from this Installation Manual to accomplish the Instructions for Continued
Airworthiness. This permission does not construe suitability of the documents. It is the applicant’s
responsibility to determine the suitability of the documents for the ICA.
Following is a suggested ICA for a Garmin GDL 49 installation. Some of the checklist items do not apply,
in which case they should be marked “N/A” (Not Applicable). In this sample, square braces are used to
indicate instances where explicit text should be substituted.
1. Introduction
[Aircraft that has been altered: Registration (N-) number, Make, Model and Serial Number]
Content, Scope,
Purpose and Arrangement: This document identifies the Instructions for Continued Airworthiness
for the modification of the above aircraft by installation of a Garmin
GDL 49.
Applicability: Applies to aircraft altered by installation of the Garmin GDL 49.
Definitions and Abbreviations: None, N/A.
Precautions: None, N/A.
Units of Measurement: None, N/A.
Referenced Publications: Garmin GDL 49 Installation Manual, P/N 190-00231-00
Garmin STC #SA01073WI
Garmin GDL 49 Sample Flight Manual Supplement,
P/N 190-00231-08
Garmin 400/500 Series Garmin Display Interfaces Pilot’s Guide
Addendum, P/N 190-00140-13 (Please see note on page 3-1)
4. Servicing Information
Unit is to be factory-serviced only by Garmin.
8. Diagrams
Refer to sections 3 and 4 of the GDL 49 Installation Manual.
16. Revision
To revise this ICA, a letter must be submitted to the local FSDO with a copy of the revised FAA
Form 337, and revised ICA. The FAA inspector accepts the change by signing Block 3 and including
the following statement:
“The attached revised/new Instructions for Continued Airworthiness (date ______) for the above
aircraft or component major alteration have been accepted by the FAA, superseding the Instructions
for Continued Airworthiness (date ______).”
Consistent with N8110.69 or Order 8110.4, Aviation Authority approved installers are hereby granted
permission to use STC #SA01073WI (see page B-2) data to modify aircraft.
The GDL 49 has received FAA Parts Manufacturer Approval (PMA) #PQ3742CE-D.