Wulfsberg COBHAM FLEXCOMM II C-5000 Installation Manual
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Wulfsberg COBHAM FLEXCOMM II C-5000 Installation Manual

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REVISION HISTORY
REV DCA
DATE
A
*I.R.
04/01/91
B
**
06/01/93
C
W302
07/21/98
D
W4507
05/31/05
E
W5685
03/31/08
F
W8457
08/21/09
G
W10755 12/20/10
H
W12857 12/07/2012 Ken Marshall
J
W13348 09/1/2013
K
W15839 04/29/2016 Ken Marshall
L
W18074 05/30/18
M
W18800 02/19/19
*I.R. = Initial Release
** = Complete revision of Rev. A
These commodities, technology or software are controlled in accordance with the United States Export Administration
Regulations, Export Classification Control Number (ECCN) EAR99. When exporting, diversion contrary to U. S. law is prohibited.
NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT CONFERS ANY RIGHT TO REPRODUCE, USE OR DISCLOSE, IN WHOLE NOR IN PART, ANY
INFORMATION CONTAINED IN THIS DOCUMENT WITHOUT WRITTEN AUTHORIZATION FROM WULFSBERG ELECTRONICS.
TEMPLATE 150-744545-01 REV. C
PRINTED
A
COPY OF THIS DOCUMENT MAY NOT BE THE
LATEST REVISION.
IT IS THE USER'S RESPONSIBILITY TO ENSURE THAT HE OR
SHE IS USING THE LATEST DOCUMENT REVISION.
THE LATEST REVISION MAY BE VIEWED OR PRINTED FROM THE
ELECTRONIC DOCUMENT DISTRIBUTION SYSTEM.
Typed signatures indicate approval. Handwritten signature approval of
this document is on file at Wulfsberg Electronics, Prescott, Arizona.
DRAWN
CHECKED
B. Patt
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C. Bretzing
A. Coburn
Dan Brasher
Ken Marshall
Tammie Mallette
Jay Jensen
James Sneed
John Blasi
Kristy Kudray
2019.02.19 11:26:16
-07'00'
IMPORTANT NOTICE
Chelton Avionics, Inc. doing business as Cobham Aerospace
Communications is responsible for full distribution and
revisions of ICA's (Instructions for Continued Airworthiness).
For inquiries regarding the content and currency of this
manual contact Chelton Avionics, Inc., 6400 Wilkinson Drive,
Prescott, Arizona, 86301. Telephone: (928) 756-1615 or refer
to the following website:
information.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION.
Refer to the DCA and associated markups for a complete description of
the changes incorporated in a revision.
APPROVED
---
---
---
R Talken
J. Jensen
S. Wild
S. Elliott
Hank Schnieder
Robert Davis
John Blasi
Jim Bachelor
Digitally signed by Heath Flor
Date: 2019.02.26 15:09:27
-07'00'
www.wulfsberg.com
for more
Chelton Avionics, Inc.
dba Wulfsberg Electronics Division
Prescott, AZ
DOCUMENT TITLE
C-5000 (Non-Digital)
INSTALLATION MANUAL
SIZE
LRU
A
C-5000
SCALE: NONE
PUBLISHED
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SH & CE
L. Evans
L. Andujo
L. Andujo
Linda Andujo
Linda Andujo
Linda Andujo
06/11/18
Digitally signed by David Urban
Date: 2019.02.20 11:01:41
-07'00'
FLEXCOMM II
DOCUMENT NUMBER
150-1355-000
DO NOT SCALE DRAWING
2019-02-26
15:45-07:00
CAGE
CODE
1WZE2
REV
M

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  • Page 1 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION. NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT CONFERS ANY RIGHT TO REPRODUCE, USE OR DISCLOSE, IN WHOLE NOR IN PART, ANY INFORMATION CONTAINED IN THIS DOCUMENT WITHOUT WRITTEN AUTHORIZATION FROM WULFSBERG ELECTRONICS. TEMPLATE 150-744545-01 REV. C CAGE Chelton Avionics, Inc.

  • Page 2: Subject Cover Page

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Installation Manual Engineering and Production by Wulfsberg Electronics, A Cobham Avionics & Surveillance Group Company Wulfsberg Electronics FLEXCOMM II C-5000 (Non-Digital) Manual Number 150-1355-000 Revision L 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM...
  • Page 3 Chelton Avionics Inc., dba Wulfsberg Electronics Division, a Cobham Avionics & Surveillance Group Company, hereafter referred to as Cobham Avionics, is located in Prescott, Arizona. For more than 25 years, Wulfsberg Electronics has distinguished itself by providing top quality avionics products for civil, air transport, and military applications.

  • Page 4: Record Of Revisions

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Record of Revisions Date Date Date Inserted Date Inserted 04/01/91 06/01/93 07/21/98 05/31/05 03/31/08 08/21/09 12/20/10 12/12/12 09/17/13 05/12/16 06/11/18 “Published on” stamp on cover page 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 4...

  • Page 5: Table Of Contents

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS SUBJECT Cover Page ........................ 2 Record of Revisions ..................... 4 Table of Contents ......................5 SECTION 1 – INTRODUCTION 1. Components ......................12 Communication Management Controller ............... 12 FLEXCOMM II ..................... 12 FLEXCOMM I ......................
  • Page 6 FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS SECTION 3 – MECHANICAL INSTALLATION (Continued) 4. Installation of Multipin Crimp Connectors ..............38 A. Contacts and Crimp Tool Information ..............38 B. Contacts and Insertion/Removal Tool Manufacturer Name and Address ....38 5.
  • Page 7 FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS SECTION 5 – CONFIGURATION AND PROGRAMMING 1. Introduction ......................133 SECTION 6 – SYSTEM CHECKOUT 1. General ........................134 A. Terms, Definitions and Limitations ............... 134 2. System Checkout ....................134 A.
  • Page 8 FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS LIST OF FIGURES C-5000 Part Numbering ..................14 Single RT-5000 with Active Antenna ..............27 Single RT-5000 with Passive Antenna ..............27 Dual RT-5000 with Dual Mic/Headset..............27 Dual Transceiver, RT-5000 and Flexcomm I ............28 Dual Transceiver, RT-5000 and Parallel Flexcomm I Transceivers ......
  • Page 9 FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS LIST OF FIGURES (Continued) P501/P502/P503 Connectors ................. 75 Connector J101 ....................80 FC-50 / FC-550 / FC-5000 Connector J1 ..............87 FC-50 / FC-550 / FC-5000 Connector J2 ..............88 FC-50 / FC-550 / FC-5000 Connector J3 ..............89 Flexcomm II System Interconnect Drawing, 152-140131 Rev.
  • Page 10 FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS LIST OF TABLES (Continued) 1-10 RT-9600 Part Numbers ..................19 1-11 RT-9600F Part Numbers ..................20 1-12 Connectors Used ....................22 System Power Requirements ................29 Component Weights ..................... 37 System Interface Connector P500 ................. 64 C-5000 Serial Interface Connector to RT-5000 P501, 502, P503 .......

  • Page 11: Table Of Contents

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual TABLE OF CONTENTS APPENDIX A: Continuous Airworthiness Instructions for Flexcomm II System ....149 1. Introduction ......................149 2. Equipment ......................149 Antenna Verification ....................149 4. Transmitter Verification ................... 149 5. Receiver Verification ....................150 6.

  • Page 12: Section 1 - Introduction

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual SECTION 1 - INTRODUCTION IMPORTANT This manual contains information pertaining to the installation of the C-5000 Communication Management Controller with FLEXCOMM II and FLEXCOMM I. FLEXCOMM II consists of the RT-5000 Transceiver, appropriate antennas, and optional equipment as required. FLEXCOMM I consists of the RT-9600 Transceiver, RT-9600F Transceiver, RT-7200 Transceiver, and optional combinations of up to three of the following FLEXCOMM Transceivers: RT-30, RT-118, RT-138(F), RT-406F, RT-450, appropriate antennas, and optional equipment as required.

  • Page 13: Flexcomm I

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual FC-5000 Logic Converter PN 153-040047-01 FC-550 Logic Converter PN 153-017851 (3) RT-5000 Mounting Trays Vertical Mounting Tray PN 300-316605-01 Horizontal Mounting Tray PN 300-316835-01 C. FLEXCOMM I (1) Transceivers RT-30 PN 400-0098-XXX (See Table 1-3) RT-118 PN 400-0119-XXX (See Table 1-4) RT-138...

  • Page 14: Part Numbering

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Note: Refer to the following for information on FLEXCOMM I antennas and installation:  FLEXCOMM I Installation Manual, WED Manual No. 150-040011-000, for information on FLEXCOMM Antennas.  WED Manual No. 150-0061-000 for information on RT-9600 and RT-7200 Antennas.

  • Page 15: Rt-5000 Part Numbers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-1. RT-5000 Part Numbers Part Number RT-5000 Description 401-015525-0101 Standard Transceiver w/o Guard 401-015525-0201 Transceiver, 30-50 MHz Guard 401-015525-0301 Transceiver, 138-174 MHz Guard 401-015525-0401 Transceiver, 406-512 MHz Guard 401-015525-0501 Transceiver w/Synthesized Guard Table 1-2. FLEXCOMM II Antenna Part Numbers Part Number Antenna Description 121-040130-01...

  • Page 16: Part Numbers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-3. RT-30 Part Numbers Part Number RT-30 Description 400-0098-000 Transceiver, FLEXCOMM Lo Band VHF, 29.70-49.99 MHz. 400-0098-001 Transceiver, FLEXCOMM Lo Band VHF, 29.70 - 49.99 MHz, with Guard Receiver 400-0098-002 Transceiver, FLEXCOMM Lo Band VHF, 29.70 - 49.99 MHz, with Guard Receiver and Guard Receiver CTCSS Tones.

  • Page 17: Rt-138F Part Numbers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-6. RT-138F Part Numbers Part Number RT-138F Description 400-014525-00 Transceiver, FLEXCOMM Hi Band VHF, 138.0000-173.9975 MHz. 400-014525-01 Transceiver, FLEXCOMM Hi Band VHF, 138.0000 - 173.9975 MHz, with Guard Receiver. 400-014525-02 Transceiver, FLEXCOMM Hi Band VHF, 138.0000 - 173.9975MHz, with Guard Receiver and Guard Receiver CTCSS Tones.

  • Page 18: Rt-406F Part Numbers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-7. RT-406F Part Numbers Part Number RT-406F Description 400-012785-00 Transceiver, FLEXCOMM UHF Band, 406.0000 511.9875 MHz. 400-012785-01 Transceiver, FLEXCOMM UHF Band, 406-0000 511.9875 MHz, with Guard Receiver. 400-012785-02 Transceiver, FLEXCOMM UHF Band, 406.0000 511.9875 MHz, with Guard Receiver and Guard Receiver CTCSS Tones.

  • Page 19: Rt-7200 Part Numbers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-9. RT-7200 Part Numbers Part Number RT-7200 Description 400-0087-000 Transceiver, RT-7200 VHF HI-Band, 138.0000 - 173.995 MHz, 14/28 VDC, 100mW Audio, Recessed Connector. 400-0087-001 Transceiver, RT-7200 VHF HI-Band, 138.00 - 173.995 MHz, 14/28 VDC, 100mW Audio, Recessed Connector, with Guard Receiver.

  • Page 20: Rt-9600F Part Numbers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-11. RT-9600F Part Numbers Part Number RT-9600F Description 400-0140-002 Transceiver, RT-9600F VHF HI-Band, 150.0000 - 173.995 MHz, 14/28 VDC, 100 mW Audio, Protruding Connector 400-0140-005 Transceiver, RT-9600F VHF HI-Band, 150.0000 - 173.995 MHz, 14/28 VDC, 100 mW Audio, Protruding Connector, with Guard Receiver 400-0140-008 Transceiver, RT-9600F VHF HI-Band, 150.0000 - 173.995 MHz, 14/28 VDC,...
  • Page 21 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-11. RT-9600F Part Numbers (Cont’d) Part Number RT-9600F Description 400-0140-076, Transceiver, RT-9600F VHF HI-Band, 150.0000 - 173.995 MHz, 400-0140-176 14/28 VDC, 100 mW Audio, Recessed Connector, with CTCSS Tones, and Voice Encryption interface compatible 400-0140-077, Transceiver, RT-9600F VHF HI-Band, 150.0000 - 173.995 MHz, 400-0140-177...

  • Page 22: Connectors Used

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-12: Connectors Used Item Designat Description Wulfsberg P/N Mil Spec P/N Radio & Control Supplies C-5000 System Interface P500 D-Sub (62 Pin female, with PN 129-215344-01 Connector backshell and two male jackscrews) Radio Option 1:...
  • Page 23 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-12: Connectors Used (cont’d) Item Designat Description Wulfsberg P/N Mil Spec P/N RT-5000 Radio Install Supplies IN-210 Connector & Tray, Flexcomm™ I 149-0059-000 Connector IN-210-1 Kit Includes: Mil-Circ, 61 Pin female, 149-0059-001 Flexcomm™ I...
  • Page 24 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-12: Connectors Used (cont’d) Item Designator Description Wulfsberg P/N Mil Spec P/N AT-550 / AT-560 / AT-5000 Hi-Split J401 TNC (Plug, straight) for use with 129-041397-01 Connector RG-393 coax TNC (Plug, 90 129-041398-01...
  • Page 25 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 1-12: Connectors Used (cont’d) Item Designator Description Wulfsberg P/N Mil Spec P/N Flexcomm I System converting to Flexcomm II System Special Adapters Adapter Cable Harness/Transceiver/Antenn 153-041054 a Tuner Adapter Cable C-5000 Parallel to Serial...

  • Page 26: Fcc Compliance

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual E. FCC Compliance This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

  • Page 27: Section 2 - System Installation

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual SECTION 2 - SYSTEM INSTALLATION General This section contains system specifications, interface information, and examples of typical system configurations for the C-5000 Communication Management Controller installed with FLEXCOMM II, FLEXCOMM I, or a configuration consisting of both FLEXCOMM II and FLEXCOMM I transceivers. System power requirements are included in Table 2-1.

  • Page 28: Dual Transceiver, Rt-5000 And Flexcomm I

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 2-4. Dual Transceiver, RT-5000 and Flexcomm I Figure 2-5. Dual Transceiver, RT-5000 and Parallel Flexcomm I Transceivers Figure 2-6. Dual Transceiver with External Encryption 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 28...

  • Page 29: Component Specifications

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 3. Component Specifications: COMPONENT POWER REQUIREMENTS C-5000 VOLTAGE: 27.5 Vdc ± 20% Aircraft CURRENT: 0.4 amps (typical) 1.3 amps (maximum external loading) FLEXCOMM II VOLTAGE: 27.5 VDC Aircraft RT-5000 STANDBY: 1.7 amps RECEIVE: 1.7 amps TRANSMIT: 10.0 amps FLEXCOMM I Transceiver System...

  • Page 30: Flexcomm Ii (Rt-5000)

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual B. FLEXCOMM II (RT-5000) (1) RT-5000 Transceiver (a) Tunability: 1.25 kHz Incremental Tuning Simplex/Semi-duplex. (b) Mode: FM/AM/P25/Trunking (c) Frequency Bands: 29.700-88.000 MHz (FM Band) 75.0 MHz RX Only 88.000-117.999 MHz (RX only)  118.000-156.000 MHz (AM Band) ...

  • Page 31: Rt-5000 Antennas

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual C. RT-5000 Antennas (1) AT-560 Antenna (a) Frequency: 29.7 - 960 MHz (b) VSWR: 2.5:1 maximum (c) Radiation Pattern: Omnidirectional in azimuth (d) Polarization: Vertical (e) Impedance: 50 ohms (f) Power: 20 Watts (g) Gain: 30 MHz, -14 dBi 88 MHz, -6 dBi 108-174 MHz, 0 dBi...
  • Page 32 FLEXCOMM II C-5000 (Non-Digital) Installation Manual (3) AT-5000 Antenna (a) Frequency: 29.7 - 960 MHz (b) VSWR: 2.5:1 maximum (c) Radiation Pattern: Omnidirectional in azimuth (d) Polarization: Vertical (e) Impedance: 50 ohms (f) Power: 20 Watts (g) Gain: 30 MHz, -15 dBi 88 MHz, -7.5 dBi 118-174 MHz, -3 dBi 225-960 MHz, 0 dBi...
  • Page 33 FLEXCOMM II C-5000 (Non-Digital) Installation Manual (5) AT-50 Antenna (a) Frequency: 29.7 - 400 MHz (b) VSWR: 2: 1 maximum (c) Radiation Pattern: Omnidirectional in azimuth (d) Polarization: Vertical (e) Impedance: 50 ohms (f) Power: 20 Watts (g) Gain: 30 MHz, -11 dBi 88 MHz, -6 dBi 108-174 MHz, 0 dBi 225-400 MHz, + 2 dBi...
  • Page 34 FLEXCOMM II C-5000 (Non-Digital) Installation Manual (7) AT-140 Antenna (a) Frequency: 29.7 - 400 MHz (b) VSWR: 2.5: 1 at 30-88 MHz 5.0: 1 at 108-117 MHz 2.5: 1 at 118-174 MHz 2.0: 1 at 225-400 MHz (c) Radiation Pattern: Omnidirectional in azimuth (d) Polarization: Vertical (e) Impedance:...

  • Page 35: Flexcomm I

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual D. FLEXCOMM I Note: Refer to FLEXCOMM I System Installation Manual, Manual Number 150-040011, for specification data on FLEXCOMM Transceivers and Antennas. Refer to VHF/FM Transceivers RT-7200, RT-9600, AN/ARC-513(V) Installation/Operators Manual, Manual Number 150- 0061-000, for specification data on RT-9600 and RT-7200 transceivers.

  • Page 36: Section 3 - Mechanical Installation

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual SECTION 3 - MECHANICAL INSTALLATION General This section contains instructions and considerations for the proper mechanical installation of the C-5000 Communication Management Controller with FLEXCOMM II and FLEXCOMM I Systems. The information presented here is necessary for the proper operation and satisfactory performance of the equipment.

  • Page 37: General Installation Requirements

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 3. General Installation Requirements A. Component Weights Component Weight C-5000 3.1 to 3.9 lbs (1.4 to1.8 kg) depending on configuration RT-5000 16.2 to 19.7 lbs (7.3 to 8.9 kg) depending on configuration AT-560 2.7 lbs (1.2 kg) AT-160 2.7 lbs (1.2 kg) AT-5000...

  • Page 38: Installation Of Multipin Crimp Connectors

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Installation of Multipin Crimp Connectors A. Contacts and Crimp Tool Information Contacts, D-Sub, Min. WED PN 129-115451-01 Crimp or Solder Positronic PN FC8122D, crimp (or equivalent) or Positronic FS8122D, solder (or equivalent) Crimp Tools C-5000 Serial RT Card interface Connector Handle - M22520/2-01 (Suggested supplier: Positioner - M22520/2-08...

  • Page 39: 3-2A Rt-5000 Install Clearance Drawing

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual For RT-5000 units using Vibration Isolators Installation clearance zones to the sides and ends of the unit should be as shown in the hatched zones. Figure 3-2a RT 5000 Installation Clearances (Vibration Isolators not shown) 150-1355-000 Rev.

  • Page 40: Installation Of Antennas

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 7. Installation of Antennas The antenna should be mounted on the bottom of the aircraft if possible. Unpainted aluminum base must make good electrical contact with airframe. Antenna should be installed on flat surface, using RF Gasket supplied with the antenna. A bead of sealant such as Dow Corning RTV-738 should be applied to the outside perimeter of the mounting surface.

  • Page 41: And At-51

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual F. AT-50 and AT-51 If antenna is installed on top of aircraft, drainage holes at smaller end of antenna should be plugged with blanking plugs and RTV. Drainage holes in antenna base flange at mounting face should not be obstructed.

  • Page 42: Antenna Mechanical Installation

    (4) P-2000/RT-2000 antennas should be mounted a minimum of 20 cm (approximately 8 in) from each other. (5) Wulfsberg recommends the use of RG-142 on most installations. Installers can substitute other types of coax or RG-400 to get better performance especially at higher frequencies.
  • Page 43 Slide outer ferrule over braid and up against connector body. Crimp outer ferrule. * for pneumatic crimp tool 227-60, use die sets indicated in this column Wulfsberg P/N Straight Right Angle 129-049080-01 .593(15.1) .250(6.4) .146(4.0)
  • Page 44 Push cable assembly forward until contact snaps into place in insulator. Slide outer ferrule over braid and up against connector body. Crimp outer ferrule. Wulfsberg P/N Straight Right Angle 129-049112-01 .687(17.4) .281(7.1) .187(4.7)

  • Page 45: C-5000 Envelope Drawing, 154-031300 Rev. P

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-1 C-5000 Envelope Drawing, Dwg. No. 154-031300, Rev. P (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 45...

  • Page 46: Rt-5000 Envelope Drawing, 154-015525 Rev. N

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-2. RT-5000 Envelope Drawing, Dwg No.154-015525, Rev N (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 46...

  • Page 47: Rt-5000 Horizontal Mount Tray Envelope Drawing, 154-016835 Rev. A

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-3. RT-5000 Horizontal Mounting Tray Envelope Drawing, Dwg No. 154-016835, Rev A (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 47...

  • Page 48: Rt-5000 Vertical Mount Tray Envelope Drawing, 154-016605 Rev. B

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-4. RT-5000 Vertical Mounting Tray Envelope Drawing, Dwg No. 154-016605, Rev B (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 48...

  • Page 49: Vibration Isolator Drawing, 246-017812 Rev. A

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-5 Vibration Isolator, 4-6 Lbs, Dwg 246-044540 Rev. A (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 49...

  • Page 50: Antenna Envelope Drawing, 121-040130 Rev. M

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-6 AT-560 Antenna Envelope Drawing, Dwg No. 121-040130, Rev. M (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 50...

  • Page 51: Antenna Envelope Drawing, 121-040129 Rev. K

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-7 AT-160 Antenna Envelope Drawing, Dwg No. 121-040129, Rev. K (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 51...

  • Page 52: At-5000 Antenna Envelope Drawing, 121-040045 Rev. G

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-8 AT-5000 Antenna Envelope Drawing, Dwg No. 121-040045, Rev. G (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 52...

  • Page 53: Antenna Envelope Drawing, 121-017850 Rev. J

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-9 AT-550 Antenna Envelope Drawing, Dwg No. 121-017850, Rev. J (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 53...

  • Page 54: Antenna Envelope Drawing, 153-017822 Rev. G

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-10 AT-150 Antenna Envelope Drawing, Dwg No. 153-017822, Rev. G (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 54...

  • Page 55: Antenna Envelope Drawing, 121-016587 Rev. M

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-11 AT-50 Antenna Envelope Drawing, Dwg No. 121-016587, Rev. M (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 55...

  • Page 56: Antenna Envelope Drawing, 121-016796 Rev. K

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-12 AT-51 Antenna Envelope Drawing, Dwg No. 121-016796, Rev. K (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 56...

  • Page 57: Antenna Envelope Drawing, 121-016584 Rev. G

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-13. AT-140 Antenna Envelope Drawing, Dwg No. 121-016584, Rev G (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 57...

  • Page 58: Antenna Envelope Drawing, 121-016821 Rev. G

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-14. AT-400 Antenna Envelope Drawing, Dwg No. 121-016821, Rev G (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 58...

  • Page 59: Antenna Envelope Drawing, 153-016586 Rev. E

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-15. FC-50 Antenna Envelope Drawing, Dwg No. 153-016586, Rev E (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 59...

  • Page 60: Fc-5000 Antenna Envelope Drawing, 153-040047 Rev. B

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-16. FC-5000 Antenna Envelope Drawing, Dwg No. 153-040047, Rev B (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 60...

  • Page 61: Antenna Envelope Drawing, 153-017851 Rev. E

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 3-17. FC-550 Antenna Envelope Drawing, Dwg No. 153-017851, Rev E (Sheet 1 of 1) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 61...

  • Page 62: Section 4 - Electrical Installation

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual SECTION 4 - ELECTRICAL INSTALLATION 1. General The following section describes the wiring requirements and options for the installation of the system. Because the system has so many features and options, it is recommended that the installer take the time to read pin descriptions and all notes on wiring diagrams before designing an installation.

  • Page 63: C-5000 System Interface Connector, P500

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Step 3: Microphone/Headset. If only one radio is installed, use the primary mic/headset port. If two radios are installed, use primary mic/headset for transceiver system #1 and secondary mic/headset for transceiver system #2. If only one mic/headset port is available on the audio panel, use the primary mic/headset port and configure the C-5000 to operate in “single mic mode”.

  • Page 64: System Interface Connector P500

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual (2) System Interface Connector P500 Pin Names. SIGNAL NAME SIGNAL NAME RT-X REXMT AUDIO OUT SYSTEM DIRECT RS-422 TX HI RT-X SELECT B XMT AUDIO IN HI RT-X REXMT CONTROL KEY OUT XMT AUDIO COMMON PLAIN/CIPHER SEL INTERNAL CIPHER SEL A EXT.
  • Page 65 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name 9, 29 - PRIMARY CARBON MIC HI/LO These pins provide a 150 Ohm input impedance for the crew microphone input. Standard Carbon Mic bias of 15V through 300 Ohms is provided. Standard modulation of 1 kHz tone at 0.25 Vrms is factory set for ±...
  • Page 66 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 43, 44 - 27.5 VDC A/C Power and A/C Power Ground These pins provide aircraft 27.5 Vdc power to the C-5000 system. Typical loading is approximately 350 mA, however with external loading by auxiliary equipment connected to ±15 V and +5 V pins provided, the current requirement can be 1.3 Amp at 27.5 Vdc and approach 2 Amps at low voltage.
  • Page 67 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 36 - EXT CIPHER ACTIVE For cipher on/off switching using an external switch this pin, when grounded, will automatically enable external encryption. If left open (unconnected) the operator can select cipher Tx Mode by pressing the C-5000 “PVT” button. 3, 4 - XMT AUDIO IN HI/COMMON This pair provides a voice band input to the transmitter(s) as selected by the crew.
  • Page 68 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 56 - PTT TO CIPHER This pin provides a ground to repeat the mic input (primary only). 15 - PTT FROM EXT CIPHER When grounded, this pin will cause the C-5000 to remain in transmit mode. Transmitter end of text messages can be transmitted after mic PTT has been released by utilizing this input as a stretched or delayed PTT input.
  • Page 69 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 16, 33 - RT-X SELECT A & B These pins, when grounded, provide an external selection (in binary format) of the selected radio system 1, 2 or 3 to be routed to the internal or external system interface for encryption or other functions connected to the system interface.
  • Page 70 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) Typical application with external encryption equipment connected to the system interface utilizes this signal as clear text receive audio to be routed to, and returned from, the external equipment in time of nonencrypted reception to the RT-X Decoded Audio Input.
  • Page 71 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 28 - AUX +5 VDC (OPTIONAL) This optional output can be used to power external auxiliary equipment. A jumper must be installed on the system interface board to activate this output. Total load for this output cannot exceed 200 mA.

  • Page 72: C-5000 Standard Installation Wiring Diagram, 147-014995 Rev. G

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-3 C-5000 Standard Installation Wiring Diagram (Sheet 1 of 3) (Dwg No.: 147-014995, Rev. G) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 72...
  • Page 73 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-3 C-5000 Standard Installation Wiring Diagram (Sheet 2 of 3) (Dwg No.: 147-014995, Rev. G) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 73...
  • Page 74 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-3 C-5000 Standard Installation Wiring Diagram (Sheet 3 of 3) (Dwg No.: 147-014995, Rev. G) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 74...

  • Page 75: C-5000 Serial Interface Connector To Rt-5000 Transceiver, P501, P502, P503

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual B. C-5000 Serial Interface Connector to RT-5000 Transceiver - P501, P502, P503 Wiring Considerations Figure 4-4. P501/P502/P503 Connectors SIGNAL NAME SIGNAL NAME DIGITAL SHIELD CHAN MEM DIS #1 RS-422 CTRL TX LO CHAN MEM DIS #2 ON/OFF RESERVED OUT SPARE B RS-422 CTRL TX HI...
  • Page 76 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Note: Verify that the C-5000 Serial RT Card is installed for this interface. Pin(s) - Signal Name 1 - DIGITAL SHIELD Shield ground connection for RS-422 CONTROL TX H and CONTROL TX L lines. Normally not used.
  • Page 77 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 14 - CIPHER / PLAIN Normally internally pulled high output pin able to sink 30mA to ground. Used to set the mode of an external encryption device. Pins 14 and 16 provide for control of devices that have different polarities for the mode set function.
  • Page 78 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 25 - RESERVED OUT SPARE B Reserved spare output. 26 - VOICE AUDIO LO IN Low side of the voice band receive audio that comes from the RT-5000. Use shielded wire.
  • Page 79 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 37 - GROUND This ground performs the same function as CONTROL GROUND pin 20. Either or both of these two pins can be used for providing a signal ground between the C- 5000 and RT-5000.

  • Page 80: Rt-5000 Transceiver Installation Wiring Diagram

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual C. RT-5000 Transceiver Installation Wiring Considerations (P/N’s 400-015525-0101 to 0501) (1) J101 Connector Figure 4-5 Connector J101 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 80...

  • Page 81: Rt-5000 Transceiver Connector J101

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual (2) RT-5000 Transceiver (P/N’s 400-015525-0101 to 0501) Connector J101 Pin Names. SIGNAL NAME SIGNAL NAME AUX AUDIO IN GUARD AUDIO INHIBIT AUX SIDETONE AUDIO HI OUT RES SPARE A AUDIO LO OUT CONTROL GND AUDIO GND RS-422 ANT TX H EXTRA WB MAIN RX AUDIO...
  • Page 82 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin - Signal Name A - AUX AUDIO IN This input will take audio from an external source unit and add to the normal transceiver audio. Not used in normal installations. B - AUX SIDETONE This input will take alert tone audio from an external source and produce headset sidetone.
  • Page 83 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin - Signal Name (Continued) N - DATA SHIELD GROUND Spare ground. P - MAIN SQUELCH ANNUNCIATE This output sinks 30 mA to ground when the main receiver signal-to-noise squelch conditions are met. R - GUARD SQUELCH ANNUNCIATE This output sinks 30 mA to ground when the guard receiver signal-to-noise squelch conditions are met.
  • Page 84 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin - Signal Name (Continued) b - PTT OUTPUT This output sinks 30ma to ground when the RT-5000 is transmitting. c - SWITCHED +15 V This output is capable of supplying +15 V ± 1.5 V at 500 mA. d - TX SWITCHED +15V When the RT-5000 is placed in transmit mode, this output supplies +15V ±...
  • Page 85 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin - Signal Name (Continued) p - MAIN SQUELCH DISABLE When this input is pulled to ground, the main squelch conditions are overridden. q - WIDE BAND MAIN RECEIVE AUDIO OUT This output is the single ended audio output. It is capable of driving a 2k Ohm impedance and has a bandwidth of 1 Hz to 27.5 kHz.
  • Page 86 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin - Signal Name (Continued) AA, BB, CC, DD - 28 VDC PWR Input Aircraft power pins. EE, FF, GG, HH - PWR GND Input Aircraft power ground pins. 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 86...

  • Page 87: Fc-550 / Fc-5000 Connector J1

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual SIGNAL NAME SIGNAL NAME RX DATA H RX DATA L GROUND TX DATA H TX DATA L GROUND GROUND GROUND Figure 4-6. FC-50 / FC-550 / FC-5000 Connector J1 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 87...

  • Page 88: Fc-550 / Fc-5000 Connector J2

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual PIN SIGNAL NAME 28 VDC DC RTN Figure 4-7. FC-50 / FC-550 / FC-5000 Connector J2 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 88...

  • Page 89: Fc-550 / Fc-5000 Connector J3

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual NOTE: FC-50 Connector J3 connects to AT-50/AT-51 antennas. These pins provide proprietary channeling information to the antenna. PIN SIGNAL NAME SIGNAL NAME Proprietary Proprietary Proprietary Proprietary Proprietary Proprietary Proprietary Proprietary Proprietary Proprietary Figure 4-8. FC-50 / FC-550 / FC-5000 Connector J3 150-1355-000 Rev.

  • Page 90: Flexcomm Ii System Interconnect Drawing, 152-140131 Rev. P

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 1 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 90...
  • Page 91 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 2 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 91...
  • Page 92 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 3 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 92...
  • Page 93 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 4 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 93...
  • Page 94 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 5 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 94...
  • Page 95 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 6 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 95...
  • Page 96 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 7 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 96...
  • Page 97 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 8 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 97...
  • Page 98 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 9 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 98...
  • Page 99 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 10 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 99...
  • Page 100 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 11 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 100...
  • Page 101 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 12 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 101...
  • Page 102 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 13 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 102...
  • Page 103 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 14 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 103...
  • Page 104 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 15 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 104...
  • Page 105 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 16 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 105...
  • Page 106 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 17 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 106...
  • Page 107 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 18 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 107...
  • Page 108 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 19 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 108...
  • Page 109 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-9. Flexcomm II System Interconnect Drawing, Dwg. No.: 152-140131 Rev. P (Sheet 20 of 20) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 109...

  • Page 110: C-5000 Communication Management Controller Installation

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual D. C-5000 Communication Management Controller Installation Wiring Considerations (1) C-5000 Parallel Interface (FLEXCOMM I) Connector - P501, P502, P503. Figure 4-10 C-5000 Parallel Interface (FLEXCOMM I) Connector - P501, P502, P503 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 110...

  • Page 111: C-5000 Parallel Interface (Flexcomm I) Connector P501 Or P502 Or P503

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual C-5000 Parallel Interface (FLEXCOMM I) Connector - P501, P502, P503 SIGNAL NAME SIGNAL NAME TONE C LINE 4 MHZ CHN LINE TX PWR LITE MIC LO/PTT 0.08 MHZ CHN LINE 0.01 MHZ CHN LINE 20 MHZ CHN LINE 0.005 MHZ CHN LINE 80 MHZ CHN LINE...
  • Page 112 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name 9, 35, 34, 57, 44, 3, 49, 53, 52, 55, 30, 10, 32, 31, 26, 4, 37, 5, 27, 28, 51 - CHANNEL LINES The channeling lines use BCD (Binary Coded Decimal) negative logic to control the Transceiver channel frequency.
  • Page 113 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 13 - MAIN RECEIVE AUDIO DISABLE Grounding this line mutes Main Receiver audio, but does not affect sidetone or Guard Receiver audio. The main squelch test function is disabled, yet the main channel indicator shows channel activity.
  • Page 114 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) Some possible uses for these include:  Antenna switching  External encoder enable (disable).  External decoder enable (disable).  Any functional or equipment switching associated with a given channel. These switch closures may be combined with a digital decoder to expand the capabilities.
  • Page 115 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 60 - UNSQUELCHED GUARD AUDIO This line provides an unsquelched audio output of the Guard Receiver for use with external audio decoders. The frequency response is approximately flat from 60 Hz to 5 kHz.
  • Page 116 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Pin(s) - Signal Name (Continued) 50 - GD VOL SET This pin, when driven to +5 VDC shall enable Guard Volume control. Note that this pin is in parallel with Pin 42. 7, 18, 24 - SPARE Spares.

  • Page 117: Flexcomm I Transceiver Install Wiring Diagram, 147-014991 Rev. B

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-11. FLEXCOMM I Transceivers Installation Wiring Diagram (RT-30, RT-118, RT-138, RT-138F, RT-450 and RT-406F), Dwg No 147-014991, Rev B (Sheet 1 of 5) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 117...
  • Page 118 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-11. FLEXCOMM I Transceivers Installation Wiring Diagram (RT-30, RT-118, RT-138, RT-138F, RT-450 and RT-406F), Dwg No 147-014991, Rev B (Sheet 2 of 5) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 118...
  • Page 119 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-11. FLEXCOMM I Transceivers Installation Wiring Diagram (RT-30, RT-118, RT-138, RT-138F, RT-450 and RT-406F), Dwg No 147-014991, Rev B (Sheet 3 of 5) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 119...
  • Page 120 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-11. FLEXCOMM I Transceivers Installation Wiring Diagram (RT-30, RT-118, RT-138, RT-138F, RT-450 and RT-406F), Dwg No 147-014991, Rev B (Sheet 4 of 5) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 120...
  • Page 121 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-11. FLEXCOMM I Transceivers Installation Wiring Diagram (RT-30, RT-118, RT-138, RT-138F, RT-450 and RT-406F), Dwg No 147-014991, Rev B (Sheet 5 of 5) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 121...

  • Page 122: C-5000 Parallel Interface, Rt-9600, Rt-9600F, Rt-7200 Transceivers

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual C-5000 Parallel Interface, RT-9600, RT-9600F, RT-7200 Transceivers (1) Connector P501, P502, P503 Figure 4-12 C-5000 Parallel Interface Connector - P501, P502, P503 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 122...

  • Page 123: C-5000 Parallel Interface Rt-9600(F), 7200 Connector P501, P502, P503

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual (2) C-5000 Parallel Interface (RT-9600(F)/7200) Connector - P501, P502, P503 SIGNAL NAME SIGNAL NAME TONE SELECT C 4 MHZ TX POWER ANNUNCIATE 0.08 MHZ 0.01 MHZ 20 MHZ 0.005 MHZ 80 MHZ GUARD TONE ENABLE TONE E RT7200: 40 MHZ RT9600(F): 0.0025 MHZ...

  • Page 124: Install Wiring Diagram (Rt-9600, Rt-9600F, Rt-7200, C-5000), 147-014992 Rev. 4

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-13. Installation Wiring Diagram (RT-9600 / RT-9600F / RT-7200 / C-5000), Dwg No 147-014992, Rev 4 (Sheet 1 of 3) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 124...
  • Page 125 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-13. Installation Wiring Diagram (RT-9600 / RT-9600F / RT-7200 / C-5000), Dwg No 147-014992, Rev 4 (Sheet 2 of 3) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 125...
  • Page 126 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-13. Installation Wiring Diagram (RT-9600 / RT-9600F / RT-7200 / C-5000), Dwg No 147-014992, Rev 4 (Sheet 2 of 3) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 126...

  • Page 127: Special Options

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual F. Special Options (1) Take Control Two C-5000's can be wired so that they can share the control of a RT-5000. To implement this feature, the installer must make use of the "Take Control" feature. Please review Figure 4-14 that shows the installation of two C-5000's sharing control of two RT-5000's.
  • Page 128 FLEXCOMM II C-5000 (Non-Digital) Installation Manual F. Special Options (Continued) Explanation of Example System (Continued) (c) Two "Take Control" switches (one for each transceiver) allow the operator to switch the control of a radio between control heads. (d) The primary headset/microphone audio's on P500 of each C-5000 are paralleled and connected to the FM1 position on the audio panel.
  • Page 129 FLEXCOMM II C-5000 (Non-Digital) Installation Manual F. Special Options (Continued) If an operator wants to control both RT-5000's from one control head, put the Take Control switches in the position that shows the status of both radios on the control head. Use the FM1 position on the audio panel when talking on RT-5000 #1.

  • Page 130: Dual C-5000/Rt-5000 With Take_Control Block Diagram

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-14 Dual C-5000/RT-5000 with Take_Control Block Diagram 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 130...

  • Page 131: C-5000 Cloning Cable Wiring Diagram, 246-042755 Rev. B

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-15. C-5000 Cloning Cable Wiring Diagram (Sheet 1 of 1) (Dwg No 246-042755, Rev B) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 131...

  • Page 132: Kvl 3000 To Dsub 9-Pin Cable Wiring Diagram, 246-049082 Rev. A

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Figure 4-16. KVL 3000 to DSUB 9-Pin Keyloader Wiring Diagram (Sheet 1 of 1) (Dwg No 246-049082, Rev A) 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 132...

  • Page 133: Introduction

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Section 5 – Configuration and Programming 1. Introduction Refer to the Operator’s Manual, P/N 150-1352-000, for more information. 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 133...

  • Page 134: General

    C-5000 as documented in the C-5000 Operator’s manual 150-1352-000 before attempting to test the installation. The C-5000 can control up to two radio systems composed of various Wulfsberg radios. It is the responsibility of the installer to understand the capabilities of the individual transceivers and associated antenna systems.

  • Page 135: B. Checkout Setup

    2. System Checkout (Continued) A. General (Continued) with any transceivers. This programming can be performed either with a PC (Wulfsberg Remote Programming Software and cable P/N 149-041389-01XX) or using the front panel buttons and knobs. Not only is it easier to use a PC but it will also provide a backup of all configuration and channel data that is loaded in the C-5000.

  • Page 136: Transmitter Tests

    (5) The final programming step is to program the desired preset channels into the C-5000 using either the Wulfsberg RP software or using the front panel knobs and buttons. Start with a limited set that will test the basic operations of the system such as: ...

  • Page 137: B. Receiver Verification

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual D. Checkout Procedure (Continued) 3.A.(2) (Continued) 3000 Hz +/ 500 Hz, adjust audio panel for more/less output. Also verify transmit frequency is correct. (3) Remove the audio source and transmit on a selected frequency; verify that sidetone audio is heard in the headset.

  • Page 138: Installation Checkout Data Tables And Checklist

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 4. Installation Checkout Data Tables and Checklist Date: ___________________ Operator: ______________________ Installation Number: ____________ C-5000 Part Number ________________ Transceiver #1 Model #: _________________________________ (RT-5000, RT-30, RT-138(F), RT-450, RT-406F, RT-9600, RT-7200) Transceiver #1 Part Number: _________________________________ Transceiver #2 Model #: _________________________________...
  • Page 139 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Step 6: (Continued) _________ RT #2 Guard Squelch Test OK _________ RT #3 Main Receiver Squelch Test OK, Volume Adjustable _________ RT #3 Guard Squelch Test OK Step 7: Transceiver Transmit Power and Modulation Tests (Record Data In Tables 6-XX) _________ RT #1 Main Power Output and Modulation OK _________...
  • Page 140 FLEXCOMM II C-5000 (Non-Digital) Installation Manual Step 12: External Encryption Tests _________ Encryption Unit Accepts Keyload _________ Transmit Encryption OK _________ Receive Encryption OK 150-1355-000 Rev. M CONFIDENTIAL AND PROPRIETARY TO COBHAM Page 140...

  • Page 141: Transceiver Test Frequencies

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Transmitter Test Data Sheet Table 6-1. RT-30 Transceiver Test Frequencies Frequency(MHz) Power Out (Watts) Modulation (Hz) Forward Power Reflected Power 30.000 34.110 41.220 45.440 48.880 Table 6-2. RT-138(F) Transceiver Test Frequencies Frequency(MHz) Power Out (Watts) Modulation (Hz) Forward Power Reflected Power...

  • Page 142: Rt-5000 Transceiver Hi Split (400 Mhz To 959.999) Test Frequencies

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 140.100 173.100 225.100 250.100 300.100 350.100 *399.100 Note: Minimum transmit power is 7.9 W with the exception of above 390 MHz (5 W Minimum). Table 6-6. RT-5000 Transceiver Hi Split (400 MHz to 959.999) Test Frequencies Frequency(MHz) Power Out (Watts) Modulation (Hz)

  • Page 143: Transceiver Test Frequencies

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual RECEIVER TEST DATA SHEET Table 6-7. RT-30 Transceiver Test Frequencies Frequency(MHz) Sensitivity (.6V) 30.000 34.110 41.220 45.440 48.880 Table 6-8. RT-138(F) Transceiver Test Frequencies Frequency(MHz) Sensitivity (.6V) 138.110 142.222 144.445 158.887 160.000 Table 6-9. RT-406F Transceiver Test Frequencies Frequency(MHz) Sensitivity (.6V) 406.110...

  • Page 144: Rt-5000 Transceiver Lo Split (29.7 To 399.999 Mhz) Test

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual Table 6-11. RT-5000 Transceiver Lo Split (29.7 to 399.999 MHz) Test Frequencies Frequency(MHz) Sensitivity (.6V) 30.100 50.100 70.100 140.100 173.100 225.100 250.100 300.100 350.100 *399.100 Note: Minimum transmit power is 7.9 W with the exception of above 390 MHz (5 W Minimum). Table 6-12.

  • Page 145: Introduction

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual SECTION 7: FLEXCOMM II Ramp Test Procedure 1. Introduction This section contains a general system checkout procedure to verify the operation of the Flexcomm II C-5000 and RT-5000 system installation. The following procedures are intended to provide a high-level system assessment in the field to assure that system parameters, selection/control, and transmit/receive functions are operating properly.

  • Page 146: Transmitter Tests

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual  A radio capable of AM/FM Modes of operation between 29.7 to 960 MHz e.g. another C-5000 system with similar radio(s) connected; AM and FM handheld radios, AM and FM base stations, etc.  Aircraft headset with microphone ...

  • Page 147: Receiver Verification

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual (1) Set the C-5000 to an AM Lo Split frequency between 30.00 and 399.00 MHz and put the RT-5000 into transmit mode. Talk into the aircraft microphone with a strong voice. This will verify the C- 5000 is communicating with the transceiver and that microphone audio is getting to the transceiver at the proper level.

  • Page 148: Guard Receiver Tests

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual (7) Perform the steps 1-6 on RT #2, if applicable. 5. GUARD Receiver Tests (1) Set the C-5000 GUARD channel(s) to a desired GUARD frequency between 30.00 and 960.00 MHz. Utilizing a handheld radio or another Multiband radio set to the same frequency, talk into the microphone with a strong voice (say and hold the word “four”).

  • Page 149: Introduction

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual APPENDIX A – CONTINUOUS AIRWORTHINESS INSTRUCTIONS FOR FLEXCOMM II SYSTEM 1. Introduction This document contains instructions for testing a FLEXCOMM II system on a periodic maintenance cycle to assure continuous airworthiness. This document is intended to supplement the individual installation and user manuals of the Flexcomm system components.

  • Page 150: Receiver Verification

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 4. Transmitter Verification (Continued) F. Set the Service Monitor to receive the transmit frequency of the selected channel. Connect the output of the radio under test to the Service Monitor RF input port with a cable less than three feet in length (refer to the Service Monitor User’s Manual).

  • Page 151: Final System Check-Out

    FLEXCOMM II C-5000 (Non-Digital) Installation Manual 8. Final System Check-out A. Reconnect the coax cable connecting the radio to the antenna. B. Place an AT-150 or similar broad band antenna 10 feet from the aircraft antenna. The antenna should be at the same elevation and have the same polarity as the antenna on the aircraft. C.

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