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September 2010
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Civil Aviation Training College
ALLAHABAD,INDIA
INDEX
S.No Chapter name Page no.
1. Familiarization with Front Panel Controls & 1
Indications.
2. Identification of various PCBs, Terminal Strips, 4
Cables & Fuses.
3. Switching on and switching off procedures from 10
Local & Remote.
4. Measurements and performance testing: 14
• Frequency
• Power
• Modulation
• Ident Code
5. Alignment, adjustments and settings: 18
• Power Supply
• Exciter section
• RF section
• Meter
• Monitor
• DCAD
6. Trouble shooting Flow Chart. 35
7. Maintenance Schedule. 37
EXERCISE- ONE
Hours:
• Describe the functions and use of the Control, Indicators, Switches and
Connectors on the front and rear panel of the Transmitter, Remote Control Unit
and Antenna Coupler Unit.
Required Materials & Conditions: you are given the following materials:
• SA 500 NDB Transmitter System
• Tool Kit
• Trainee’s Handout
Instructions/Procedure:
• Observed the front as well as rear panel of Transmitter and identify all the
components on it and record its name and function on the observation sheet.
• Observed the Remote Control Unit and identify all the components on it and
record its name and function on the observation sheet.
• Observed the Antenna Coupler Unit and identify all the components on it and
record its name and function on the observation sheet.
Exercise: Identification of various PCBs, Terminal Strips, Fuses and Cables NDB
Transmitter System Model SA500.
• Describe the functions and purpose of the various PCBs, Terminal Strips, Fuses
and Cables of the Transmitter, Remote Control Unit and Antenna Coupler Unit.
Required Materials & Conditions: you are given the following materials;
• SA 500 NDB Transmitter System
• Tool Kit
• Trainee’s Handout
Instructions/Procedure:
• Pull out the front panel/drawer and identify the various PCBs, Terminal Strips,
Fuses and Cables in Auto Transfer Unit, Exciter unit and P A Unit. Record their
name and function on the observation sheet.
• Pull out the front panel/drawer and identify the various PCBs, Terminal Strips,
Fuses and Cables in the Remote Control Unit. Record their name and function
on the observation sheet.
• Pull out the front panel/drawer and identify the various PCBs, Terminal Strips,
Fuses and Cables in the Antenna coupler Unit. Record their name and function
on the observation sheet.
• Describe the purpose/functions of each switches and controls in the front panel.
Required Materials & Conditions: you are given the following materials;
• SA 500 NDB Transmitter System
• Tool Kit
• Trainee’s Handout
Instructions/Procedure:
• In the previous exercise you have already been familiarized with the front panel
switches and controls. Read the handout and follow the instructions to:
01. Ensure AC mains voltage normal 220V ± 10% single phase 50 Hz.
02. Incase secondary battery supply is available; ensure battery voltages are normal
+24VDC and +144VDC.
03. Ensure antenna is connected to the RF output of the equipment.
04. It is suggested a 500 watts 50 ohms dummy-load is connected to the local
“Standby RF output” to avoid any accidental damage to the equipment.
05. Check for the Local Control front panel switch positions
06. Check for the Exciter Unit front panel switch positions
i. Meter: OFF
08. In the Local Control panel put the System Power ON/OFF switch to ON
position
Observe:_________________________________________________________
________________________________________________________________
09. In the Exciter Unit put the Primary Power switch to ON position in Tx.1
(Secondary Power switch to ON position only if secondary battery supply is
available)
Observe:_________________________________________________________
________________________________________________________________
11. Now put the Transmitter Power switch in Local Control panel to ON position.
Tx. 1 should come up.
Observe:_________________________________________________________
________________________________________________________________
01 Reflected Power
02 Forward Power
03 Modulation
04 PA1 Voltage
05 PA1 Current
06 PA2 Voltage
07 PA2 Current
13. If all readings are normal, put the Transmitter Power switch in the Local
Control panel to OFF position. Primary Power and RF switches in Exciter Unit
of Tx.1 to OFF position.
14. Next, select Primary Transmitter in Local Control panel to Tx.2 position.
Primary Power and RF switches in Exciter Unit of Tx.2 to ON position.
Observe:_________________________________________________________
________________________________________________________________
15. Put the Transmitter Power switch in Local Control panel to ON position. Tx. 2
should come up.
Observe:_________________________________________________________
________________________________________________________________
01 Reflected Power
02 Forward Power
03 Modulation
04 PA1 Voltage
05 PA1 Current
06 PA2 Voltage
07 PA2 Current
17. If all readings are normal, put the Transmitter Power switch in the Local
Control panel to OFF position. Primary Power and RF switches in Exciter Unit
of Tx.2 to OFF position.
19. Ensure Mains AC supply and Secondary Battery supply switches are put OFF.
REMARKS:
• In normal operation in the field stations both Tx.1 and Tx.2
Exciter Units Primary Power switch RF switch will be kept at
ON position. Incase, secondary battery supplies are available,
then Secondary Power switch shall also be kept in ON position.
Monitor switch to ENBL and Mode switch to ID.
• Primary Transmitter switch in the Local Control panel, to Tx.1
or Tx.2 as desired.
• Transmitter switching ON or OFF is performed through Power
ON/OFF switch in the Local Control panel.
• For remote operation, Remote switch in the Local Control
panel should be kept in ENBL position.
Exercise: Carry out the Performance Testing of NDB Transmitter System Model
SA500.
Required Materials & Conditions: you are given the following materials:
• SA 500 NDB Transmitter System
• Oscilloscope
• Digital multimeter
• Frequency Counter
• 50 Ohm Dummy Load
• Trainee’s Handout
Primary Set Up
A. With all power removed, connect the 50 Ohm Non- inductive Dummy to the RF
output as required.
B. Set the POWER SEC switch (if applicable) to OFF.
C. Adjust RF control to its full low level CCW position.
D. Adjust MOD control to its full low level CCW position.
E. Set MODE switch to the CARR position.
F. Set RF METER switch to the FRWD position.
G. Set MONITOR switch to the DSBL position.
H. Set RF switch to ON.
I. Apply power and set the POWER PRI switch to the ON position.
Observations:
Operating Tolerances Measured Result
Frequency Frequency
357 KHz +/- 5Hz
Observations:
Required voltage Tolerances Measured Result
(P-P) for 100% Modulation
Power
400 Vp-p +/- 2.5%
(400 Vp-p = 400 watts)
Observations:
Required Tolerances Measured Result
Modulation Modulation
95% 85%-95%
No Shutdown:
RESULT:
No Tone Shutdown:
• Set the MODE switch to CARR position.
• Unit should shutdown within 60 seconds.
RESULT:
Continuous Tone Shutdown:
• Set the MODE switch to CONT position.
• Unit should shutdown within 60 seconds.
RESULT:
RESULT:
VSWR Shutdown:
• Turn the RF LEVEL control to its full CCW position (zero power).
• Set the RF METER switch to REFL position.
• Set MODE switch to to the CARR position.
• Set the RF switch to OFF position.
• Disconnect the 50 Ohm load/antenna.
• Set the RF switch to ON position.
• Cycle the the MONITOR switch from RST to ENBL. Wait 5 seconds.
• Slowly increase RF LEVEL control to 20% reflected power.
• Unit should shutdown at approximately 20 %.
• Reconnect the 50 Ohm load/antenna. Reset the RF METER to the
FRWD position.
Observations:
Measured Tx. - 1 Tx. - 2 Result
Forward power
Reflected power
Exercise: Carry out the Alignment, adjustments and settings of NDB Transmitter
System Model SA500.
• Power Supply
• Exciter Section
• PA Section
• Meter
• Monitor Control
• DCAD
Required Materials & Conditions: you are given the following materials:
• SA 500 NDB Transmitter System
• Oscilloscope
• Digital Multimeter
• Frequency Counter
• 50 Ohm Dummy Load
• Trainee’s Handout
¾ There are two sets of four fuses for Tx. 1 and Tx. 2 respectively
i. A1F1 – F4 15 amps 250 V slow blow (F1 & F2 ac mains fuse,
F3 144V battery supply and F4 24 V battery supply)
ii. A2F1 – F4 15 amps 250 V slow blow (F1 & F2 ac mains fuse,
F3 144V battery supply and F4 24 V battery supply)
¾ There are there fuses F1 – F3 of 1 amp F1 & F2 for ac mains and F3 for
24 battery supply. These supplies are for +24 V control voltage
generation in Local Control.
• PA Drawer
NOTE: One should be very careful while carrying out the measurements and should be
done in the presence of the instructors. It may result to personal injury and/or may
result damage to the equipment due to high voltages. PA power supply C3 and C4
capacitors’ top screws (+) are having High Voltage DC. It is recommended to drain C3
& C4 before attending the equipment.
• Carrier Frequency setting. The desired frequency is set using the programming
switches on the KWOSYN PWB (see fig) S2, S3 & S4 in KHz. The frequency
is read directly on the rotary switches. To add 0.5 KHz jumper J1 to be closed.
Select S1 in the C1 position if the frequency is between 190 and 320 KHz and
in the C2 position if the frequency is between 320 and 535 KHz. Adjust C10 to
programmed frequency at TP1 (Carrier Frequency ± 5 Hz.).
Result: ____________
• For 1020 Hz ± 5 Hz adjust R2, using oscilloscope adjust R10 at TP1 for 5 to 8
Vpp (8Vpp approx.)
Result: _____________
• The code sequence is loaded into DIP switches U1 through U6 (see fig.),
starting at U6 and working toward U1. Switch 1 of U6 is always in the open
position. If all of these switches are not used, it is necessary to leave the next 4
switches past the last code bit open. Using the CSR Program Example figure,
program station ident. Verify that ident is correct on Keyer Code PWB at DS1.
Result: ____________
5.3 PA SECTION
i. Check RF LEVEL and MOD are fully CCW.
ii. Connect 50-ohm dummy load.
iii. Switch RF to ON.
PA voltage should read 0. Result: _____________
PA current should read less than 0.3 A. Result: ___________
iv. Set MONITOR to DSBL. LED should glow. Result: __________
v. Set MODE switch to CARR.
vi. Switch PA READ to VOLTAGE and adjust RF LEVEL for a reading of 20
V.
vii. Switch PA READ to CURRENT. Current should be approximately 0.5 A.
Result: ___________
viii. Adjust RF for rated power using oscilloscope voltage on the dummy load –
ix. For 400 Watts output PA1 and PA2 readings as per Factory Acceptance Test
(FAT). Current should read 4.4 ± 0.8 A. Voltage should read 55 ± 5 V.
Parameter Voltage Current
FAT Result FAT Result
PA1 59 4.0
PA2 55 4.0
5.5 MONITOR
i. Turn RF LEVEL fully CCW. Place MONITOR switch in DSBL.
ii. On Monitor PWB turn R2 fully CW.
iii. Turn OFF all power. Disconnect dummy load. Re-apply power.
iv. Turn MODE switch to CARR and RF METER switch to FRWD. Turn RF
LEVEL 20% on power meter.
v. Turn R2 CCW until DS2 LED fully illuminates.
vi. Turn RF LEVEL fully CCW. Reconnect dummy load.
vii. Turn RF LEVEL to desired shutdown level (typically @ 50%).
viii. Place DC voltmeter probe in TP3 (orange) with MODE switch in IDENT.
ix. Turn R6 CW until voltmeter deflects upward during ident to approx. 5.7-7
vdc.
x. Turn RF level CW to 100% power. Place meter probe in TP1. Turn mode
switch to CONT, turn RF meter to READ. Turn MODto70%. Put mode
switch to lDENT and RF METER switch to FRWD. Adjust R22 CCW until
voltage builds to approx. 9.5 vdc and resets to near zero. (If climbing to 9.75
volts at first, turn R22 CW until it idents from .6 to 2.5 volts and then adjust
R22 as stated above).
xi. Put MONITOR switch to RST and then ENBL. Transmitter should
shutdown after approx. 45 seconds with a ‘N’ light. Result: ___________
xii. Put MONITOR switch to RST and then DSBL. Put MODE switch to
CONT, RF METER switch to READ. Adjust MOD to 95%, put MODE
switch back to IDENT and RF METER switch back to FRWD. MONITOR
switch to RST and then ENBL. Check for at least two minutes that
transmitter does not shutdown.
xiii. Set MODE switch to CONT. Transmitter should shutdown after approx. 45
seconds with a ‘C’ light. Result: ___________
xiv. Move MODE switch to IDENT, MONITOR switch to RST and then ENBL.
Move MODE switch to CARR. Transmitter should shutdown in approx. 45
seconds with a ‘N’ light. Result: ___________
xv. Turn MODE switch to CARR, MONITOR switch to RST then ENBL, turn
RF LEVEL to 50%, MODE switch to IDENT and the transmitter should
shutdown approx. 45 seconds with a ‘P’ light. Result: ___________
xvi. Turn RF LEVEL fully CCW. Turn power OFF. Disconnect dummy load.
Turn power ON, MODE switch to CARR, MONITOR switch to RST and
5.6 DCAD
i. On DCAD PWB turn R4 fully CW.
ii. R4 adjusts the DC Auto Disconnect to approximately 19 V. To make this
adjustment at any battery voltage, the following procedure can be followed.
Exercise: Trouble Shooting Flow Chart NDB Transmitter System Model SA500.
• Carry out the module level fault finding following the Flow Chart.
Required Materials & Conditions: you are given the following materials:
• SA 500 NDB Transmitter System
• Tool Kit
• Trainee’s Handout
Instructions/Procedure:
• The Trouble Shooting Flow Chart will be studied.
• Some fault finding exercises will be carried out to explain the flow chart.
Required Materials & Conditions: you are given the following materials:
• SA 500 NDB Transmitter System
• Tool Kit
• Trainee’s Handout
Instructions/Procedure:
• Read the Daily, Weekly, Monthly and Quarterly Maintenance Schedule from
your handout and practice the same.
NOTE: This is a general guideline for Preventive Maintenance. The approved AAI
Hqrs Maintenance Schedule to be followed at station.
General
01 Room Temperature 22° C ± 2° C
03 Battery voltage:
24 V > 19 V
144V
Equipment Checks
01 Exciter
i. Refl Pwr < 20 %
02 RF
i. PA1 Volt 55 V ± 5 V
v. PA1 LED ON
iii. Tx Power ON
LED ON
04 ACU
i. Antenna Curr Reading at commission
± 20 %
05 Carry out external
cleaning
TX.-1 TX.-2
01 Carry out power measurements
TX.-1 TX.-2
01 Check carrier frequency (Station Freqs ± 0.01 %)
ii. No Tone