Kac-1052 - Maintenance Manual 006-15640-0001 - 1

COMPONENT MAINTENANCE MANUAL
KAC 1052 Antenna Coupler
MANUAL NUMBER 006-15640-0001 REVISION 1 JANUARY, 2004
WARNING Prior to export of this document, review for export license requirement is needed.
COPYRIGHT NOTICE 2003, 2004 Honeywell International Inc. Reproduction of this publication or any portion thereof by any means without the express written permission of Honeywell is prohibited. For further information contact the Manager of Technical Publications, Honeywell, Olathe, KS 66061. Telephone: (913) 712-0400.
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______________________________________________________________________ Honeywell Aerospace Electronic Systems 23500 West 105th Street Olathe, Kansas 66061
Component Maintenance Manual with illustrated parts list
KAC 1052 Antenna Coupler

Part No. 064-01074-0101 Manufacturer Honeywell
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PRINTED IN U.S.A PUB. NO. 006-15640-0001
Jan/2004
NOTE IF ANY UNUSUAL OR SPECIAL SERVICE PROBLEMS ARISE, CONTACT HONEYWELL CUSTOMER SUPPORT DEPARTMENT.
PROPRIETARY NOTICE This document contains proprietary information and such information may not be disclosed to others for any purpose, nor used for manufacturing purposes without written permission from Honeywell.
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COMPONENT MAINTENANCE MANUAL KAC 1052 Antenna Coupler / Part No. 064-01074-0101
TRANSMITTAL INFORMATION
TO HOLDERS OF: HOLDERS OF COMPONENT MAINTENANCE MANUAL, PUB. NO. 006-15640-0000, KAC 1052 ANTENNA COUPLER (PART NO. 064-01074-0101). REVISION NO. 001, DATED Jan/2004
Revision History Table of Revisions Revision No. 1 Revision Date Jan/2004 Date Put in Manual (full revison of manual) By
Highlights This revision contains these changes: Table of Highlights Task/Page (various) Description of Change Corrected clerical errors. Effectivity
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Use or disclosure of information on this page is subject to the restrictions in the proprietary notice of this document.
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Task/Page
Description of Change
Effectivity
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RECORD OF REVISIONS
For each revision, put the revised pages in your manual and discard the superseded pages. Write the revision number and date, the date put in the manual, and the incorporators initials in the applicable columns on the Record of Revisions.
Revision Number Revision Date Date Put In Manual Revision Number Revision Date Date Put In Manual
By
By
01/04
(full rev.)
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Revision Number Revision Date Date Put In Manual By Revision Number Revision Date Date Put In Manual By
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RECORD OF TEMPORARY REVISIONS

Instructions on each page of a temporary revision tell you where to put the pages in your manual. Remove temporary revision pages only when discard instructions are given. For each temporary revision, put the applicable data in the record columns on this page. Temp Rev. No. Status Task Location
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Temp Rev. No.
Status
Task Location
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SERVICE BULLETIN LIST

The following Service Bulletins have been incorporated in this manual. Manual Revision Number Manual Revision Date
ATA Number
Coverage
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ATA Number
Manual Revision Number
Manual Revision Date
Coverage
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LIST OF EFFECTIVE PAGES

SUBHEADING AND PAGE Title T-1 Jan/2004 T-2 Jan/2004 Transmittal Information TI-1 Jan/2004 TI-2 Jan/2004 Record of Revisions RR-1 Jan/2004 RR-2 Jan/2004 Record of Temporary Revisions RTR-1 Jan/2004 RTR-2 Jan/2004 Service Bulletin List SBL-1 Jan/2004 SBL-2 Jan/2004 List of Effective Pages LEP-1 Jan/2004 LEP-2 Jan/2004 LEP-3 Jan/2004 LEP-4 Blank Table of Contents TOC-1 Jan/2004 TOC-2 Jan/2004 TOC-3 Jan/2004 TOC-4 Jan/2004 List of Figures LOF-1 Jan/2004 LOF-2 Blank List of Tables LOT-1 Jan/2004 LOT-2 Blank DATE SUBHEADING AND PAGE Introduction INTRO-1 INTRO-2 INTRO-3 INTRO-4 INTRO-5 INTRO-6 Description and Operation 1 2 3 4 5 6 7 8 F 9 10 11 12 13 14 15 16 F 17 18 F 19 20 21 22 23 24 25 26 27 DATE Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Blank Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Blank Jan/2004 Blank Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Blank Jan/2004 Blank Jan/2004 Blank Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004 Jan/2004
indicates a changed, added, or deleted page
F indicates a right foldout page with a blank back LF indicates a left foldout page with a blank front.
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SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE
Description and Operation (cont) 28 Jan/2004 29 Jan/2004 30 Jan/2004 Testing and Fault Isolation 1001 Jan/2004 1002 Jan/2004 1003 Jan/2004 1004 Jan/2004 1005 Jan/2004 1006 Jan/2004 1007 Jan/2004 1008 Jan/2004 1009 Jan/2004 1010 Jan/2004 Schematics and Wiring Diagrams 2001 Jan/2004 2002 Blank Disassembly 3001 Jan/2004 3002 Jan/2004 3003 Jan/2004 3004 Blank Cleaning 4001 Jan/2004 4002 Jan/2004 4003 Jan/2004 4004 Jan/2004 4005 Jan/2004 4006 Blank Check 5001 Jan/2004 5002 Jan/2004
Repair 6001 Jan/2004 6002 Jan/2004 Assembly 7001 Jan/2004 7002 Jan/2004 7003 Jan/2004 7004 Jan/2004 7005 Jan/2004 7006 Jan/2004 7007 Jan/2004 7008 Blank Fits and Clearances 8001 Jan/2004 8002 Blank Special Tools, Fixtures, and Equipment 9001 Jan/2004 9002 Jan/2004 F 9003 Jan/2004 9004 Blank Special Procedures 11001 Jan/2004 11002 Blank Removal 12001 Jan/2004 12002 Blank Installation 13001 Jan/2004 13002 Blank Servicing 14001 Jan/2004 14002 Jan/2004 Storage 15001 Jan/2004 15002 Blank
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SUBHEADING AND PAGE Rework 16001 16002 Illustrated Parts List 10001 10002 10003 10004 F 10005 10006 F 10007 10008 DATE Jan/2004 Blank Jan/2004 Jan/2004 Jan/2004 Blank Jan/2004 Blank Jan/2004 Blank SUBHEADING AND PAGE DATE
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SUBHEADING AND PAGE DATE SUBHEADING AND PAGE DATE
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TABLE OF CONTENTS DESCRIPTON PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1. How to Use This Manual (Task 23-10-06-99C-801-A01) . . . . . . . . . . . . . . . . . . . . 1 A. General Information (Subtask 23-10-06-99F-001-A01) . . . . . . . . . . . . . . . . . . . 1 B. Acronyms (Subtask 23-10-06-99F-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1. Physical Description (Task 23-10-87-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 A. General (Subtask 23-10-07-87-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 B. Packaging (Subtask 23-10-07-87-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 (1) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 C. Chassis (Subtask 23-10-07-87-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 D. Switches and Knobs (Subtask 23-10-07-87-004-A01) . . . . . . . . . . . . . . . . . . . . 7 E. Connector (Subtask 23-10-07-87-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 (1) RF Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 (2) P10521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 (3) P10522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 F. Cooling (Subtask 23-10-07-87-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 G. Internal Connections (Subtask 23-10-07-87-007-A01) . . . . . . . . . . . . . . . . . . . 7 H. Major Subassemblies (Subtask 23-10-07-87-008-A01) . . . . . . . . . . . . . . . . . . 11 (1) PS and Interface Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 (2) CPLR Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 (3) Sensor and Relay Drive Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .11 (4) Shunt Capacitor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 (5) Series Capacitor Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 (6) Coil Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 2. Functional Description (Task 23-10-07-87-802-A01) . . . . . . . . . . . . . . . . . . . . . . 12 A. General (Subtask 23-10-07-87-009-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Theory of Operation (Subtask 23-10-07-87-010-A01) . . . . . . . . . . . . . . . . . . . 12 (1) General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 (2) RF Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 (3) Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 (4) Bridging Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 (5) CPLR Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 (6)Power Supply and Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 (7) Interface Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 TESTING AND FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 1. How to Use (Task 23-10-07-99C-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 A. General (Subtask 23-10-07-99F-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 1001 2. Test Philosophy (Task 23-10-07-75-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 1001 A. Airplane Fault Isolation (Subtask 23-10-07-94-001-A01) . . . . . . . . . . . . . . . 1001
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3. Procedure (Task 23-10-06-75-802-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 A. Shop Fault Isolation (Subtask 23-10-07-81-001-A01) . . . . . . . . . . . . . . . . . 1001 B. Bench-Test Harness Return to Service Test Solution (Subtask 23-10-07-75-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004 (1) Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004 (2) Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004 (3) Antenna Coupler Tuning Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1004 (4) High-SWR Retune Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1007 (5) Bridging Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1007 C. KPA 1052 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009 4. Automatic Test Requirements (Task 23-10-07-75-803-A01) . . . . . . . . . . . . . . 1009 A. General (Subtask 23-10-07-75-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009 B. Equipment and Materials (Subtask 23-10-07-75-005-A01) . . . . . . . . . . . . . 1009 C. HF ATE System Test Solution (Subtask 23-10-07-75-006-A01) . . . . . . . . . 1009 SCHEMATICS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 1. Task (Task 23-10-07-99C-803-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 A. General (subtask 23-10-07-99F-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 2. Equipment and Materials (Task 23-10-07-94-802-A01) . . . . . . . . . . . . . . . . . . 3001 A. General (Subtask 23-10-07-94-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 3. Procedure (Task 23-10-07-03-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 A. General (Subtask 23-10-07-03-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 (1) Side Plates (2) MPBC36547A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002 (2) Series Cap Board (26) MDLW11386D . . . . . . . . . . . . . . . . . . . . . . . . . .3002 (3) Shunt Cap Board (25) MDLW11385F . . . . . . . . . . . . . . . . . . . . . . . . . . .3002 (4) Coil Board (27) MDLW11390E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002 (5) Sensor and Relay Drive Board (24) MDCW10907D . . . . . . . . . . . . . . . .3003 (6) Shields (29) MPSC30332A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3003 (7) CPLR Control Board (23) MDLW11428 . . . . . . . . . . . . . . . . . . . . . . . . .3003 (8) Power Supply and Interface Board (22) MDBW10546B . . . . . . . . . . . . .3003 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001 1. Task (Task 23-10-06-99C-804-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001 A. General (Subtask 23-10-06-99F-007-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 4001 2. Equipment and Materials (Task 23-10-06-94-803-A01) . . . . . . . . . . . . . . . . . . 4001 A. General (Subtask 23-10-06-94-003-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001 3. Procedure (Task 23-10-06-16-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4002 A. General (Subtask 23-10-06-16-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4002 (1) Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002 (2) Cleaning Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002 (3) Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003 (4) Chassis, wired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4004 (5) Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
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CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 1. Task (Task 23-10-07-99C-805-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 A. General (Subtask 23-10-07-99F-008-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 5001 2. Equipment and Materials (Task 23-10-07-94-804-A01) . . . . . . . . . . . . . . . . . . 5001 A. General (Subtask 23-10-07-94-004-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 3. Procedure (Task 23-10-07-21-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 A. General (Subtask 23-10-07-21-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001 (1) Structural Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001 (2) Electrical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 1. Task (Task 23-10-06-99C-806-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 A. General (Subtask 23-10-06-99F-009-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 6001 2. Equipment and Material (Task 23-10-06-94-805-A01) . . . . . . . . . . . . . . . . . . . 6001 A. General (Subtask 23-10-06-94-005-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 3. Procedure (Task 23-10-06-35-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 A. General (Subtask 23-10-06-35-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001 (1) General Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002 (2) Detailed Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 1. Task (Task 23-10-07-99C-807-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 A. General (Subtask 23-10-07-99F-010-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 7001 B. Staking Compounds, Sealants, Thermal Compounds, and Lubricants to be Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 (Subtask 23-10-07-99F-011-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001 C. Screw and Nut Torque Values (Subtask 23-10-07-99F-012-A01) . . . . . . . . 7002 2. Equipment and Materials (Task 23-10-07-94-806-A01) . . . . . . . . . . . . . . . . . . 7003 A General (Subtask 23-10-07-94-006-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7003 3. Procedure (Task 23-10-07-43-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7003 A. General (Subtask 23-10-07-43-001-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7003 (1) PS and Interface Board (22) MDBW10546B . . . . . . . . . . . . . . . . . . . . .7003 (2) CPLR Control Board (23) MDLW11428 . . . . . . . . . . . . . . . . . . . . . . . . .7004 (3) Shield Assembly (29) MPSC30332A . . . . . . . . . . . . . . . . . . . . . . . . . . .7004 (4) Sensor and Relay Drive Board (24) MDCW10907D . . . . . . . . . . . . . . . .7004 (5) Coil Board (27) MDLW11390E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004 (6) Shunt Cap Board (25) MDLW11385F . . . . . . . . . . . . . . . . . . . . . . . . . . .7005 (7) Series Cap Board (26) MDLW11386D . . . . . . . . . . . . . . . . . . . . . . . . . .7005 (8) Side Plates (2) MPBC36547A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7005 B. Pressurization (Task 23-10-07-43-002-A01) . . . . . . . . . . . . . . . . . . . . . . . . 7006 1. Pressurization with dry nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7006 2. Pressurization with dry air pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7007 FITS AND CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 9001 1. Task (Task 23-10-06-99C-808-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001 A. General (Subtask 23-10-06-99F-011-A01) . . . . . . . . . . . . . . . . . . . . . . . . . 9001 2. Return to Service Testing (Task 23-10-06-94-807-A01) . . . . . . . . . . . . . . . . . . 9001 A. General (Subtask 23-10-06-94-007-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001 SPECIAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11001 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12001 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13001 SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14001 STORAGE (INCLUDING TRANSPORTATION) . . . . . . . . . . . . . . . . . . . . . . . . . . 15001 1. Storage (Task 23-10-06-55-801-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15001 A. Storage After Assembly (Subtask 23-10-06-55-001-A01) . . . . . . . . . . . . . 15001 REWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16001 ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10001 1. Introduction (Task 23-10-07-99C-809-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . 10001 A. General (Subtask 23-10-07-99F-014-A01) . . . . . . . . . . . . . . . . . . . . . . . . 10001 B. Parts Listing (Subtask 23-10-07-99F-015-A01) . . . . . . . . . . . . . . . . . . . . . 10001 (1) FIND NO. Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001 (2) PART NUMBER Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001 (3) DESCRIPTION Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001 (4) QTY Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10001
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LIST OF FIGURES DESCRIPTION PAGE
Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01) . . . . . . . . . . . . . 1 Figure 2 KAC 1052 Subassembly Locations (Task 23-10-07-99B-802-A01) . . . . . . . 6 Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01) . . . . . . . . . . 9 Figure 4 Simplified Block Diagram (Task 23-10-07-99B-804-A01) . . . . . . . . . . . . . . 13 Figure 5 Matching Network Element Selection (Task 23-10-07-99B-805-A01) . . . . . 14 Figure 6 RF Matching Network (Task 23-10-07-99B-806-A01) . . . . . . . . . . . . . . . . . 15 Figure 7 Impedance Sensors Block Diagram (Task 23-10-07-99B-807-A01) . . . . . . 21 Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01) . . . . . . . . 23 Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01) . . . . . . . . . . . 24 Figure 10 Power Supply and Interface Block Diagram (Task 23-10-07-99B-810-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 11 PS and Interface Surge Protection Circuits (Task 23-10-07-99B-811-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01) . . . . . . . . . . . . 1005 Figure 1002 KAC 1052 Bridging Amplifier Test Setup (Task 23-10-07-99B-813-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008 Figure 7001 Side Plate Installation (Task 23-10-07-99B-814-A01) . . . . . . . . . . . . 7006 Figure 9001 HF ATE System (Task 23-10-06-99B-815-A01) . . . . . . . . . . . . . . . . 9002 Figure 9002 KHF 1050 System Bench-Test Harness (Task 23-10-06-99B-816-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003 Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) . . . . . . . 1005 Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) . . . . . . . 1007
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LIST OF TABLES DESCRIPTION PAGE
Table INTRO-1. Acronyms (Task 23-10-07-99A-801-A01) . . . . . . . . . . . . . . . . . . . . . . 5 Table 1 Leading Particulars (Task 23-10-07-99A-803-A01) . . . . . . . . . . . . . . . . . . . . 3 Table 2 KAC 1052 Subassemblies (Task 23-10-07-99A-804-A01) . . . . . . . . . . . . . . . 5 Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01) . . . . . . . . . . . . . . . . . . 17 Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01) . . . . . . 29 Table 5 Interface Signal Description J10522 (Task 23-10-07-99A-807-A01) . . . . . . 30 Table 1001 KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01) . . . . . . . . . . 1002 Table 1002 KAC 1052 Pressure Indication (Task 23-10-07-99A-809-A01) . . . . . . 1003 Table 4001 Recommended Cleaning Materials (Task 23-10-07-99A-810-A01) . . 4002 Table 7001 Sealants, Staking Compounds, Thermal Compounds, and Lubricants (Task 23-10-07--99A-809-A01) . . . . . . . . . . . . . . . . 7002 Table 7002 Typical Screw and Nut Torque Values (Task 23-10-07-99A-810-A01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002 Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01) . . . . . . . . . . . . . 10002
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COMPONENT MAINTENANCE MANUAL KRX 1052 Antenna Coupler / Part No. 064-01074-0101
INTRODUCTION
1. How to Use This Manual (Task 23-10-06-99C-801-A01) A. General Information (Subtask 23-10-06-99F-001-A01) (1) This publication is written to the Air Transport Association of America (ATA) Spec 2200 and will be revised as necessary to show current information. (2) All front matter consists of a title page that displays the equipment name and part number, and the ATA and document numbers assigned to the manual, a RECORD OF REVISIONS page for recording revision incorporation, a RECORD OF TEMPORARY REVISIONS page for recording temporary revision (yellow page) insertion prior to formal revision, a SERVICE BULLETIN LISTthat includes a brief description of the reason for the bulletin, and the date that Service Bulletin information was incorporated into the manual, a TABLE OF CONTENTS, a LIST OF FIGURES and a LIST OF TABLES. (3) DESCRIPTION AND OPERATION section contains an equipment illustration, table of leading particulars, a general description, and a theory of operation for the electronic assemblies to assist in understanding the circuitry for fault isolation purposes. (4) TESTING AND FAULT ISOLATION section contains a functional test to enable maintenance personnel to assess the operational condition of the equipment, calibration procedures for electronic or mechanical adjustment as necessary, troubleshooting guide to assist in fault isolation, and complete electrical wiring and schematic diagrams. (5) SCHEMATICS AND WIRING DIAGRAMS section contains complete electrical wiring and schematic diagrams. (6) DISASSEMBLY section contains procedures for disassembling the equipment to the part replacement level. Complete overhaul procedures are not provided. Specific procedures are intended to be a supplement to, and are correlated to, the Illustrated Parts List (IPL). (7) CLEANING section contains general cleaning procedures, which should be observed during repair and/or part replacement where applicable. (8) CHECK section contains general areas to visually observe during disassembly and assembly to assure that equipment operational standards are met.
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(9) REPAIR section contains specific instructions for repairing areas of the equipment not specifically covered in the ASSEMBLY section. (10)ASSEMBLY section contains all specific instructions necessary for part replacement and to supplement the IPL. Special instructions for use of adhesives, wires, heat sink compounds, etc., not covered in the IPL, are included. Special assembly sequence requirements, as applicable, are provided. (11)FITS AND CLEARANCES section contains a list of dimensional values, torques, etc., if required during assembly. These parameters are also specified in the ASSEMBLY section where applicable. (12)SPECIAL TOOLS, FIXTURES AND EQUIPMENT section contains a list of all equipment required to perform procedures specified in the other manual sections. (13)STORAGE (INCLUDING TRANSPORTATION) section contains storage and transportation instructions. (14)ILLUSTRATED PARTS LIST section contains illustrations and parts lists for all equipment assemblies, subassemblies and components. The illustrations and parts lists are item-number keyed for location of parts, and list quantities, part numbers, and part descriptions. An introduction to the IPL relates how it is used, definitions used, equipment designators and alphanumerical indices for parts.
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B. Acronyms (Subtask 23-10-06-99F-002-A01)

TERM ACP ADLP AGC ALC AME ASCII ATE A3A A3H A3J BCD BIT BITE BNC BPS C CCITT CMC CMU COM COMM CW dB dBc dBm DSP DEFINITION Antenna Coupler (or equivalent test panel) Airborne Data Link Processor Automatic Gain Control Automatic Level Control Amplitude Modulated Equivalent American Standard Code for Information Interchange Automatic Test Equipment Single sideband reduced carrier voice emission (R3E) Single sideband full carrier emission (H3E, H3D) Single sideband suppressed carrier emission (J3E, J3D) Binary Coded Decimal Built-In Test Built-In Test Equipment RF connector type Bits Per Second Celcius Consultive Committee for International Telegraphy and Telephony (ITU) Central Maintenance Computer Communication Management Unit Communication Communication Continuous Wave (unmodulated) Decibels Decibels relative to carrier Decibels relative to 1 mW Digital Signal Processor
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TERM EMI Fc FM GHz HF HFDL Hg HIRF H3D H3E ICAO IF ITU IMD j J3D J3E K KBPS KHz KPN LSB LSB MCDU MHz mic
DEFINITION ElectroMagnetic Interference carrier Frequency Frequency Modulated Gigahertz (109) High Frequency (2-30 MHz) High Frequency Data Link Mercury (chemical element) High Intensity Radiated Field Single sideband full carrier data emission Single sideband full carrier voice emission (formerly A3H) International Civil Aviation Organization Intermediate Frequency International Telecommunications Union Inter Modulation Distortion The square root of -1 Single sideband suppressed carrier data emission Single sideband suppressed carrier data emission (formerly A3J) Kelvin KiloBits Per Second Kilohertz (103) King Part Number Least Significant Bit Lower SideBand emission Mode Control Display Unit Megahertz (106) microphone
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TERM MPS MSB NLT NMT PEP pF PC PTT PTT RAM RF R3E RX/EX SDI SBH SBL SELCAL SINAD SQH SQL SSB H USB VRMS VSWR W
DEFINITION Minimum Performance Standard Most Significant Bit Not Less Than Not More Than Peak Envelope Power Picofarad (10-12) Personal Computer Push To Talk (or Transmit) German Post, Telephone and Telegraph Authority Random Access Memory Radio Frequency Single sideband reduced carrier voice emission (formerly A3A) Receiver/Exciter Source/Destination Identifier Syllabic squelch for a high signal environment Syllabic squelch for a low signal environment Selective Calling Signal including noise and distortion Signal to noise squelch for a high noise environment Signal strength squelch for a low noise and high signal environment Single Sideband Microhenry (10-6) Upper Sideband emission Root Means Square Voltage Voltage Standing Wave Ratio Watt
Table INTRO-1. Acronyms (Task 23-10-07-99A-801-A01)

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Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01) Dwg. No. SDNFC5037L
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DESCRIPTION AND OPERATION

1. Physical Description (Task 23-10-87-801-A01) A. General (Subtask 23-10-07-87-001-A01) (1) The KAC 1052 Antenna Coupler automatically tunes the 50 ohm coaxial output of the 200 Watt PEP Transmitter Power Amplifier to the aircraft antenna impedance for each of the operating frequencies actually used by the KHF 1050 System (also known as Primus HF 1050). The network configurations for each tune are stored in non-volatile memory so that once the KAC 1052 is tuned in to the aircraft antenna and particular operating frequency, it will remember that tune. In the event that the antenna impedance changes, the KAC 1052 will retune to the new impedance. An additional use of the coupler is to provide a good signal from the antenna to the KRX 1053 in the receive mode.
Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01)

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Each tune that is remembered is also utilized on other nearby frequencies. For example, the tuning values determined at 6550.0 kHz will be utilized from 6547.4 kHz through 6553.8 kHz. If a frequency is selected beyond this range, the KAC 1052 will find a new tune. In general, the same tune will be used over a range of 0.1% of the operating frequency. At an operating frequency of 3000.0 kHz, the same tune will be used over a range of approximately 3 kHz. At 22000 kHz, the same tune will be used over a range of approximately 22 kHz. A variety of tuning networks are available in the KAC 1052, to allow the antenna coupler to match most commonly used aircraft HF antennas. Sensor circuitry and a CPU (microprocessor) internal to the KAC 1052 guide the antenna coupler to selection of a network that provides a complementary match for the impedance of the antenna. The same CPU circuitry communicates with the KRX 1053 Receiver/Exciter and the KPA 1052 Power Amplifier. The KAC 1052 also provides a communication path between the KRX 1053 and the KPA 1052. With some antenna configurations, high RF voltages can be developed at certain operating frequencies. In order to prevent this high voltage from arcing over internally at high altitudes, the KAC 1052 is pressurized with nitrogen. In the event that nitrogen should leak out of the coupler, the KAC 1052 first generates a low pressure warning message that is sent to the controller. An additional drop in pressure will result in a low pressure fault condition, which will force the output power of the KHF 1050 system to be reduced to 50 W until pressure is restored. The KAC 1052 antenna coupler has an internal bridging amplifier that is used in receive mode when the antenna is not tuned. The bridging amplifier is also used in a dual configuration. In a KHF 1050 dual-system configuration, both systems share one antenna. If the two systems are tuned to different frequencies, the strongest reception is normally realized on the primary system (which is defined as the last system to have transmitted) because the antenna is tuned to that frequency. The secondary system (the opposite system from the primary system) will generally realize somewhat weaker reception. To help minimize the effects of this weaker reception, the bridging amplifier built into the KAC 1052 is automatically switched in to help amplify the signal received by the secondary system. Also in a dual-system configuration, when the primary system is transmitting, the connections to the antenna in the secondary system are opened up. As a result, reception on the secondary system is disabled.
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The KHF 1050 does not require any external accessories for dual-system operation, other than a specifically fabricated coaxial cable to allow interconnection of the two KAC 1052 Antenna Couplers to the antenna. Six printed circuit assemblies are used in the KAC 1052. The matching networks reside on three printed circuit assemblies; the Shunt Cap Board, the Series Cap Board and the Coil Board. A Sensor and Relay Driver Board monitors the impedance of the network and provides relay drive current. The Coupler Control Board contains the CPU that controls the operation of the KAC 1052 and the KPA 1052. Interface circuitry to the KPA 1052 and KRX 1053 is located on the PS and Interface Board, along with the KAC 1052 power supply. The mechanical configuration of the KAC 1052 Antenna Coupler is mainly composed of chassis assembly, two side plates, shield assembly and mounting brackets. An HN connector on the back of the unit provides for connection to an antenna, while connectors for interface with the rest of the KHF 1050 system are on the front of the unit. CHARACTERISTIC Overall Dimensions Weight (approximate) DESCRIPTION 13.6 L x 4.75 W x 7.24 H in. 434 cu. in. 16.4 lbs.
Temperature Range: Operating Storage -55C to +70C (See STORAGE (INCLUDING TRANSPORTATION)) +55,000 ft. +27.5Vdc @ 3A 37 Pin (J10521) and 9 Pin (J10522) D-Subs Table 1 Leading Particulars (Task 23-10-07-99A-803-A01) (sheet 1 of 2)
Altitude: Power Requirements: Connectors:
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CHARACTERISTIC TSO:
DESCRIPTION C31d, C32d, DO-160D Env. cat .

[A2F2X]BAB[RS]EXXXXXA[BZ]A[BZ]A[TT]L[A3E3]XAA
Applicable Document:
RTCA DO-160D, DO-163 FCC Part 80, 87 and 90 200 Watts PEP. Less than 1.5:1 typical, 3:1 maximum 50 msec (nominal) for previously tuned freq. 2 to 10 sec (nominal) if not previously tuned.
Power Capability: VSWR: Antenna Tuning Time: Antenna Matching Capability: Wire Antenna:
Grounded Wire Antenna: 10-25 feet grounded (55,000 ft max ALT) 25-30 feet may be grounded or ungrounded (30,000 ft max ALT if ungrounded)
NOTE: Altitude limits not applicable if KAC 1052 is mounted in a pressurized environment. Internal protection: High SWR due to change in antenna impedance will force a retune. An internal bleeder resister provides a static discharge path to ground. Should the coupler not be able to tune the antenna at a given frequency, a tune fault will result after the coupler has attempted different network configurations to tune the antenna. Table 1 Leading Particulars (Task 23-10-07-99A-803-A01) (sheet 2 of 2)
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B. Packaging (Subtask 23-10-07-87-002-A01) (1) General Two side panels attach to a welded chassis assembly. Seals between the side panels and the chassis maintain the internal pressure. Removal of the side panels allows access to the printed circuit assemblies. Internal to the KAC 1052 is a shield assembly consisting of a shield cap, shield plate and two supports. This shield isolates the microprocessor circuitry from the matching network RF circuitry. The shield assembly is located between the Coupler Control Assembly and the Sensor and Relay Driver Assembly. Brackets attached to each end of the KAC 1052 allow for mounting the unit to a mounting tray in the aircraft. A 37-pin D-shell connector is located on the front of the unit to allow for interfacing with the rest of the KHF 1050 system. The front of the KAC 1052 also includes a BNC connector for connection to the KPA 1052, and a 9-pin D-shell connector that is used for ground maintenance purposes. Both a fill valve and a pressure relief valve are also located on the front panel. On the rear of the unit is an HN connector for connection to the antenna, and a ground post. Additionally, a vent plug is mounted on the rear of the KAC 1052 to enable the purging of air from the unit as it is pressurized. The KPA 1052 amplifies the KTR 1053 exciter output to 200 Watts PEP or 50 Watts of carrier power in AM. This amplified signal is routed through the KAC 1052, which matches the various impedances of the antenna to the 50 ohm output of the transmitter. The received signals, from the antenna, pass through the antenna coupler to the KTR 1053.
Nomenclature Power Supply and Interface Board Coupler Controller Board Sensor and Relay Drive Board Shunt Capacitor Board Series Capacitor Board Coil Board Item Number 22 23 24 25 26 27 Part No. DEXX-CBL-103 DHXX-CDC-1083B DHXX-CCN-338 DHXX-CSC-590B DHXX-CSC-591B DHXX-CSC-592B
Table 2 KAC 1052 Subassemblies (Task 23-10-07-99A-804-A01)

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Figure 2 KAC 1052 Subassembly Locations (Task 23-10-07-99B-802-A01)

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C. Chassis (Subtask 23-10-07-87-003-A01) (1) The chassis assembly serves as a support for the printed circuit boards. All connectors used for external interface also mount to the chassis. The Shunt Cap Board, Series Cap Board and Coil Board mount directly to tabs on the chassis, whereas the Sensor and Relay Driver Board, Coupler Control Board and the PS and Interface Board mount to the chassis assembly via standoffs. The side panels, as well as all connectors and valves that penetrate the chassis assembly, are sealed to retain the nitrogen pressure inside the unit. A ground stud is pressed into the chassis assembly to provide a return path for antenna RF current. D. Switches and Knobs (Subtask 23-10-07-87-004-A01) (1) The KAC 1052 does not contain any switches or knobs. E. Connector (Subtask 23-10-07-87-005-A01) (1) RF Output Connector The HN-type RF output connector, for connection to the antenna, is on the rear surface of the antenna coupler. (2) P10521 A 37-pin D-shell connector, P10521, is located on the front of the unit to allow for interfacing with the rest of the KHF 1050 system. DC power, along with serial and parallel interfaces to the KRX 1053 and KPA 1052, connect to this connector. (3) P10522 A 9-pin D-shell connector is located on the front of the unit to allow for interfacing with shop maintenance computers and test functions. F. Cooling (Subtask 23-10-07-87-006-A01) (1) No forced air cooling is required for this Unit. G. Internal Connections (Subtask 23-10-07-87-007-A01) (1) See Figure 3 KAC 1052 Internal Connections (Task 23-10-07-99B-803-A01).
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H. Major Subassemblies (Subtask 23-10-07-87-008-A01) (1) PS and Interface Board Assembly The PS and Interface card is located at the front panel and composed of a power supply switching circuit, voltage regulators, voltage-current convertor for APC, RS422 interface driver and surge protection for interface signals. The card supplies 28V, 12V and 5V DC power to all circuit cards and has all interface connectors to communicate with other LRUs. (2) CPLR Control Board Assembly The Coupler Control Card is located between the PS and Interface card and the Shield Assembly and composed of a CPU, CPLD, EEPROM, analog interface, RS232 interface driver, reference voltage generator, pressure sensor, temperature sensor and voltage monitor. The card administers all operations to be needed and monitoring the state of the Unit. (3) Sensor and Relay Drive Board Assembly The Sensor and Relay Drive Card is located between the Shield Assembly and three matching network boards, and composed of an impedance sensor. This card includes the RF power level detector, 3dB attenuator, relay driver, bridge amplifier and some of the relays for RF network determination. The card detects input impedance and provides them to the Coupler Control, converts serial relay signals to parallel relay signals and amplifies received signals and provides to the RX/EX. (4) Shunt Capacitor Board Assembly The Shunt Capacitor Board card is located between the Series Capacitor Board and the Coil Board card and composed of shunt capacitors and relays constituting the RF networks, arrestor and discharging resistor. (5) Series Capacitor Board Assembly The Series Capacitor Board card is located at the right side of the unit and composed of series capacitors and relays constituting the RF networks. The capacitors are sometimes connected as shunt capacitor arm of the RF networks.
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(6) Coil Board Assembly The Coil Board card is located at left side of the unit and composed of inductors and relays constituting the RF networks. The inductors are connected as shunt inductor arm or series inductor arm of the RF networks. 2. Functional Description (Task 23-10-07-87-802-A01) A. General (Subtask 23-10-07-87-009-A01) (1) This section gives the functional description and block diagrams for the KAC 1052. Each subsection tells about the function of the shop-replaceable units and how they interrelate to each other. The functional operations described in this chapter refer to the KAC 1052 in the test environment, not on the aircraft. This section provides the information required to effectively perform fault isolation at the shop-replaceable unit level. The shop technician should be familiar with the systems that interface with the KAC 1052 as well as the signal flow from circuit card assembly to circuit card assembly in order to effectively achieve this level of maintenance. B. Theory of Operation (Subtask 23-10-07-87-010-A01) (1) General The KAC 1052 Antenna Coupler is a component of a KHF 1050 Radio Communications System. It receives 200W PEP HF signals from the KPA Power Amplifier (PA) and feeds the power to an aircraft antenna through its impedance transformation networks. Received signals from the antenna pass through the KAC 1052 and KPA 1052 Power Amplifier (PA) to the KRX 1053 Receiver/Exciter (RX/EX). The Unit is normally installed near an antenna inside the aircraft fuselage. Placement within close proximity to the antenna is important in the reduction of feed line loss. In order to prevent high-voltage arcing at high altitudes, the unit is filled with nitrogen and keeps its internal pressure consistent.
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Figure 4 Simplified Block Diagram (Task 23-10-07-99B-804-A01)
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(2) RF Networks The RF matching circuit of the unit is composed of three circuit branches; shunt capacitor, series capacitor and inductor circuit. Each branch has a dedicated card; Shunt Capacitor Board, Series Capacitor Board and Coil Board. Each branch is composed of 12 to 13 elements that are combination of capacitors or inductors and switching relays. The element values are designed to provide both sufficient resolution at the upper limit frequency and wide coverage range at the lower limit frequency. Each capacitor or inductor is connected and disconnected by relays. Figure 5 Matching Network Element Selection (Task 23-10-07-99B-805-A01) shows the way in which inductor and capacitor elements are switched in and out by relays. The values of these elements increase in a binary manner. For example, if the capacitance value of C101 is 1, the relative capacitance value of C102, C103 will be 2 and 4. Combined inductance or combined capacitance of each branch is the sum of all applied elements in that branch.
Figure 5 Matching Network Element Selection (Task 23-10-07-99B-805-A01) Refer to Figure 6 RF Matching Network (Task 23-10-07-99B-806-A01). The Shunt Cap Board has 13 shunt capacitor elements that can be connected in parallel. It also contains three relays that are used to determine the network. The maximum capacitance is approximately 5600 pF.
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Up to 13 capacitors can be connected in parallel on the Series Cap Board to provide the series capacitor elements for the tuning network. This board also has three network determining relays. The maximum capacitance is approximately 1500 pF. The Coil Board has 12 inductor elements that can be connected in series. It also contains three relays that are used to determine the network type. The maximum inductance is approximately 48 uH.
Figure 6 RF Matching Network (Task 23-10-07-99B-806-A01) The unit has many circuit configurations that enable wide matching impedance range. Combinations of network determination relays set the circuit configuration. Available circuit configurations are listed in Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01). The unit tries to set the most efficient circuit among these configurations during tuning sequence.
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No.
Circuit
Schematic
Ls on
Lp on
LC on
LH1
LH2
LHSR
Cin on
Cs on1
Cs on2
C1p
Cp in
Cp out
Note
Cp-Cs
Cs-Cp
Cp-Ls
Ls-Cp
Cs-Pl
Cp-Cs-Lp
Note: O = relay on
X = either relay on or off, depending on inductor value
Blank = relay open
Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01) (sheet 1 of 2)

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No.
Circuit
Schematic
Ls on
Lp on
LC on
LH1
LH2
LHSR
Cin on
Cs on1
Cs on2
C1p
Cp in
Cp out
Notes
Lp-Cs-Cp
Clp-Ls-C3p
Ls-Cp-Cs
10
Cp-Ls-Cs
11
Ls-Cs-Cp
12
THRU
Note: O = relay on
X = either relay on or off, depending on inductor value
Blank = relay open
Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01) (sheet 2 of 2)

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(3) Sensors The KAC 1052 has the following sensors; impedance sensors, pressure sensor, temperature sensor and power supply voltage sensor. The impedance sensors are located on the Sensor & Relay Drive. The other sensors are located on the Coupler Control Board. The impedance sensors are divided into magnitude detector, phase detector, angle detector, resistance (R) detector, conductance (G) detector and VSWR detector. Figure 7 Impedance Sensors Block Diagram (Task 23-10-07-99B-807-A01) shows the block diagram of the impedance sensors on the Sensor & Relay Drive Board.
Figure 7 Impedance Sensors Block Diagram (Task 23-10-07-99B-807-A01) The magnitude (Zin) detector measures the magnitude of line impedance. The detector compares the magnitude of line voltage with that of current. If magnitude of line voltage is smaller than line current (impedance is less than 50 Ohms), the signal Zin<Zo will be low. The phase detector monitors the phase of line impedance. The detector detects phase difference between line voltage and current. If line voltage lags line current (impedance is capacitive), the signal PH<0 will be low.
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The angle detector generates DC voltage proportional to the phase difference between line voltage and line current. The signal has no polarity and it will be 5Vdc at maximum phase difference of 90 degrees. The resistance detector measures the magnitude of real part line impedance. The detector compares the sum of the line voltage and current with the magnitude of the line voltage. If the real part of line impedance is smaller than 50 Ohms, the signal Rin<Zo will be low. The conductance detector determines the magnitude of real part line admittance (conductance). The detector compares the sum of the line voltage and current with the magnitude of the line current. If the line conductance is smaller than 1/50 Siemens, the signal Gin>Go will be high. The VSWR detector detects forward voltage (Vf) and reflected voltage (Vr) of line. Each voltage is compared to each other to generate VSWR signals on the CPLR Control card. The signal Vf is also used to generate PWR ON and PWR Hi signals. The PWR ON signal informs the CPU that RF power level is valid and enables tuning operation. The PWR Hi signal informs the CPU that RF power level is too high to tune and enables detune detection. The pressure sensor detects internal absolute pressure of the unit. The device U42 outputs differential DC voltage Vo+ and Vo- proportional to the pressure followed by the high input impedance differential amplifier composed of U43 and U44A. The gain of the differential amplifier is designed such that the output voltage will be approximately 4Vdc with 30-psi pressures. This voltage is provided to CPU and converted digital value to detect pressure-warning level. The comparator U44B detects the low-pressure alarm and informs CPU via CPLD as PRESS ALM. The alarm level is set to approximately 11.9 psia. The temperature sensor detects internal temperature of the unit. The device R428 varies its resistance in response to temperature and shunt resistors R426 and R427 linearize the resistance. The output voltage of the amplifier U45A is approximately proportional to absolute temperature and will be approximately 2Vdc at 400 degrees K. This voltage is provided to the CPU and converted to a digital value to compensate the pressure value at room temperature. The power supply voltage monitor observes the combined voltage of 12Vdc and 5Vdc used in the unit. The combined voltage is provided to the CPU and converted digital value. If the 12Vdc and /or 5Vdc have failed, the CPU detects power supply alarm.
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(4) Bridging Amplifier The Bridging Amplifier is mounted on the Sensor Relay Drive Board. This amplifier is activated under three conditions: In the event the KAC 1052 has not been tuned up on the receive frequency During dual-system operation (in the secondary system) When the KHF 1050 system is first turned on, before any transmission is made
When activated, the amplifier amplifies the received signal from the antenna and provides the signal to the KRX 1053 Receiver/Exciter via the KPA 1052 Power Amplifier. Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01) shows a block diagram of the Bridging Amplifier. The amplifier is composed of single NPN transistor and transformer used for feedback circuit. The impedance matching transformer is inserted at its input circuit to convert the impedance from 50 Ohm to about 400 Ohm. The approximate gain of the amplifier is 9 to 12 dB at the frequency range from 2 to 30MHz. The internal oscillator and output level detector are incorporated to detect the failure of the amplifier. The frequency of the oscillator is approximately 4MHz. To protect the amplifier, the input circuit is connected to ground and the output is connected to an internal 50 Ohm resistor during transmission on the KHF 1050 system.
Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01)
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(5) CPLR Control The CPLR CONTROL is composed of CPU, CPLD, EEPROM, analog interface, RS232C interface driver, reference voltage generator, pressure sensor, temperature sensor and voltage sensor. The card administers all operations and monitoring of the state of the unit. Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01) shows the block diagram of the card. Functions of this card are as follows: Serial communication with RX/EX Observation of the discrete signals from RX/EX Setting of operation mode of PA according to frequency and emission mode Observation of the PA alarm ON-OFF control of relays for the RF matching network Observation of impedance signals fed from SENSOR & RLY DRV card Measurement and observation of pressure, temperature and power supply voltage Storing, restoring and initializing the tuning parameters in the EEPROM Serial communication with external PC via RS-232C port Execution Built-In-Test (BIT), reporting and recording of the results of BIT
Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01)

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CPU U1 performs a main role in the unit. It is the highly efficient single chip microcomputer, which makes the 32-bit H8/300H a core and integrates the peripheral functions needed for system configuration. The H8/300H operates in a 32-bit configuration and is capable of 16Mbytes linear address area. The integrated peripheral functions in the device is composed of 128kbytes ROM, 4kbytes RAM, 16-bit and 8-bit timers, programmable pattern controller (TPC), watch dog timer (WDT), 3-channel serial communication interfaces (SCI), 10-bit A/D converter, D/A converter, I/O ports, DMA controller etc. The CPU has the flexibility to change its configuration and operation mode. The CPU has seven operation modes that change address and data bus widths. The ROM on this card has 128kbyte flash ROM that enables it to be reprogrammed. The operating frequency is approximately 20MHz. External address and data buses are not used. CPLD U2 is a programmable logic device that enables users to rewrite the hardware configuration. In this card the CPLD is applied to interface between the CPU and other card or other LRUs. EEPROM U5 is the non-volatile memory and has the capacity of 32kbytes. The device is directly connected with the CPU. The device stores tuning parameters, strap information, some of the latest tuning failure results and BIT results. The recorded data can be read by maintenance software via RS-232C port J10522. Some failures are reported to the RX/EX. All analog signals are fed to the CPU and converted from analog voltages to digital data by and internal 10-bit A/D converter. The converter has 8-port channels selected by time division. The following signals are input to the converter via analog switched U29 to U31: Forward power voltage fed from SENSOR & RLY DRV: Vf Reflected power voltage fed from SENSOR & RLY DRV: Vr Magnitude of RF input voltage (only during tuning operation): Vin Magnitude of RF input current (only during tuning operation): Iin Absolute Kelvin temperature: Temp Magnitude of phase difference between RF voltage and current (only during tuning operation): Angle Absolute internal air pressure: Press Combined voltage of 12V and 5V regulated power supply: Vcc Output level of bridge amplifier: V-BRDG RF peak voltage of internal 50 Ohm resistor on the SENSOR & RLY DRV: Vdum
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These signals are used to determine the tuning algorithm and failures detection of pressure, power supply voltage, bridge amplifier and sensor. RS-232C interface driver IC U6 converts bi-directionally between differential signals and TTL level signals. The TTL signals are provided to the CPU via the CPLD. Reference voltage generator U4 generates a stable 5Vdc required by the CPU for A/D converting. Pressure sensors, temperature sensors and the voltage monitor are described in Paragraph 2.B.(3) Sensors. Connector J16 is a port for programming the CPLD with dedicated cables and parallel port of a PC. Connector J17 is a port for programming the CPU with dedicated cables and writer and serial port of a PC. Connector J18 is a port for debugging software operation of the CPU and direct monitoring the state of relays at the factory. (6)Power Supply and Interface The PS & Interface card is composed of power supply switching circuit, voltage regulators, voltage-current converter for APC, RS422 interface driver and surge protection for interface signals. The card supplies 28V, 12V and 5V DC power to all cards and has all interface connectors to communicate with other LRUs. The power supply switching circuit is comprised of a controller IC U51, a switching N-channel FET Q2, a resistor for detecting excessive current, an overvoltage detector, an undervoltage detector and PWR CONT controller. If the PWR CONT pin is grounded, the FET Q1 will turn off. And if the voltage of U51-1 is over about 1.25Vdc, the FET Q2 will turn on. As a result, 28Vdc power will be supplied to relays and regulator ICs U52 and U53 that are used by CPLR CONTROL card and SENSOR & RLY DRV card. The power-on voltage is determined by a voltage divider comprised of R43 and R44.
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Figure 10 Power Supply and Interface Block Diagram (Task 23-10-07-99B-810-A01) If the voltage at U51-5 is above approximately 1.25Vdc, the FET Q2 will turn off to protect internal circuit devices from damage due to excessive voltage. The threshold voltage is set to 36 to 38Vdc by series connected Zener diodes CR83 and CR84. This pin is also used for determining the time interval caused by an over-current trip. The time interval is determined to approximately 180 mSec by timing capacitors C48 and C49. Resistor R45 detects excessive load current. If the current is over 4.5 to 5.1 ADC, U51 shuts off FET Q51. Then U51 will try to turn Q2 on at approximately 180 mSec intervals until the cause of current trip is removed. Two voltage regulator ICs U52 and U53 generate regulated 12 Vdc and 5 Vdc each. Output voltage of 12 Vdc is determined by a voltage divider comprised of R51, R52 and R53.
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The output voltage is controlled by the voltage across U52-2 and U52-3 which is approximately 1.2 Vdc. As a result, the output voltage is approximately 12 Vdc. The voltage-current converter for the automatic power control (APC) is comprised of a rail-to-rail operational amplifier, IC U63, and an NPN transistor, Q3. The circuit converts the forward power voltage Vf fed from SENSOR & RLY DRV to direct current for the APC feedback system during tuning operation of the unit. The output current is proportional to 2-Vf. For example, If Vf is 0V, the output current is approximately 20 mA. If Vf is approximately 2 Vdc, the current is nearly 0 mA. In the event the APC line between the KAC 1052 and the KPA 0152 is broken, the power amplifier will default to minimum output power. This system will protect both the PA and the antenna coupler from excessive RF output power during tuning operation. RS-422 interface driver IC U61 converts between differential signals and TTL level signals in a bi-directional manner. The TTL signals are provided to CPU on the CPLR CONTROL card. Opto-coupler interfaces are adopted for all discrete input signals (excluding RS-422 receiving signal and PWR CONT signal) to isolate internal circuits from aircraft noise. All discrete output signals from the CPLR CONTROL card are fed to the KRX 1053 and KPA 1052 via this card. All discrete input and output pins are protected against induced surge voltage by inserting series resistors and shunt surge absorbers (Silicon Transient Voltage Suppressor: TVS) excluding primary power input. Figure 11 PS and Interface Surge Protection Circuits (Task 23-10-07-99B-811-A01) shows three kinds of surge protection circuits adopted on this card.
Figure 11 PS and Interface Surge Protection Circuits (Task 23-10-07-99B-811-A01)

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This card has two interface connectors that are directly mounted for interfacing with external devices. Sub-D connector J10521 is used for communication with the RX/EX and PA, and J10522 is used for connecting to the serial port of an external PC. (7) Interface Signal Descriptions The discrete interface signals of CONTROL connector J10521 are described in Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01), and those of TEST connector J10522 are described in Table 5 Interface Signal Description J10522 (Task 23-10-07-99A-807-A01).
Pin 20 1 21 2 11 27 28 30 33 36 34 35 3 22 4 23 29 10 12 9 Signal Name PRI PWR PRI PWR RTN PWR CNT PWR CNT RTN RC COM MATCH ON BRDG ON BFRD KEY PA BFRD KEY PC COM PA ALM #1 PA ALM #2 STRAP A STRAP B STRAP COM SPARE CR COM TUNE FAIL TUNE REQ EXTR INHB Source/Dest External External External External RX/EX RX/EX RX/EX RX/EX PA PA PA PA External External External N/A RX/EX RX/EX RX/EX RX/EX I/O Input N/A Input N/A Input Input Input Input Output Input Input Input Input Input Input I/O Output Output Output Output Description +27.5 Vdc Primary Power Primary Power Return Power ON/OFF Control Power ON/OFF Control Return RX/EX Input Common Matching Circuit ON Bridge Amplifier ON Buffered Key ON Buffered Key ON PA Input Common PA Alarm Signal #1 PA Alarm Signal #2 Antenna Type Strap A Antenna Type Strap B Strap Common Spare Interface Port RX/EX Output Common Tune Fail Signal Tune Request Signal RX/EX TX Inhibit Properties Power In GND Low in active GND +15V Low in active High in active Low in active Low in active +15V High in active High in active Low in active Low in active GND Low in active +12V High in active High in active High in active
Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01) (sheet 1 of 2)

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Pin 32 15 16 17 18 19 6 24 7 25 8 14 37 26 5 13 31 Signal Name CP COM PA INHB PA SI PA SCK PA RCK PA ALM RST RCA RCB CRA CRB BUS COM APC H APC L EXTR COM FG FG FG Source/Dest PA PA PA PA PA PA RX/EX RX/EX RX/EX RX/EX RX/EX PA PA RX/EX N/A N/A N/A I/O Output Output Output Output Output Output Input Input Output Output N/A Output Output N/A N/A N/A N/A Description PA Output Common PA TX Inhibit PA Mode Serial Data PA Mode Serial Clock PA Mode Serial Strobe PA Mode Rest Serial Receive Data + Serial Receive Data Serial Send Data + Serial Send Data RS-422 BUS Common APC Feedback + APC Feedback Exciter Common Frame Ground Frame Ground Frame Ground Properties +12V High in active High in active High in active High in active Low in active RS-422 + RS-422 RS-422 + RS-422 GND Current loop Current loop return GND GND GND GND
Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01) (sheet 2 of 2)
Pin 3 2 5 9 7 4
Signal Name TEST TXD TEST RXD TEST COM LEAK WRN INH PRESS GND
Source/Dest External PC External PC External PC External External N/A
I/O Output Input N/A Input Output N/A
Description Serial Send Data + Serial Receive Data Test Common Air Leak Warning Inhibition Absolute Pressure Level Ground
Properties RS-232C RS-232C GND Low in active Analog Voltage GND
Table 5 Interface Signal Description J10522 (Task 23-10-07-99A-807-A01)

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TESTING AND FAULT ISOLATION

1. How to Use (Task 23-10-07-99C-802-A01) A. General (Subtask 23-10-07-99F-005-A01) (1) This section describes procedures for testing and fault isolation of the KAC 1052 Coupler. (2) Equivalent materials and equipment to the items listed in the Return to Service testing options are permitted. It is the responsibility of the user to find equivalent part numbers. (3) The KAC 1052 can be tested as part of a KHF 1050 system using a bench-test harness or as a stand-alone unit with a properly configured HF Automated Test Equipment (ATE) System. Paragraph 3.B.B. Bench-Test Harness Return to Service Test Solution (Subtask 23-10-07-75-001-A01) for the bench-test harness procedure and to Paragraph 4.C. HF ATE System Test Solution (Subtask 23-10-07-75-006-A01) for the ATE system procedure. 2. Test Philosophy (Task 23-10-07-75-801-A01) A. Airplane Fault Isolation (Subtask 23-10-07-94-001-A01) (1) The test philosophy for the KAC 1052 is to test and fault isolate to the defective circuit card assembly or other authorized subassembly in accordance with this manual. The line mechanic should remove the KAC 1052 only when the unit is not operating properly. 3. Procedure (Task 23-10-06-75-802-A01) A. Shop Fault Isolation (Subtask 23-10-07-81-001-A01) The KAC 1052 contains six printed circuit boards. The information in Table 1001 KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01) and Table 1002 KAC 1052 Pressure Indication (Task 23-10-07-99A-809-A01) can be used to assist in troubleshooting the antenna coupler to the card level. Due to the complexity of the KAC 1052, it may be necessary to return the unit to the factory for troubleshooting on computer-based equipment.
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Symptom Unit totally inoperative
Primary Cause/Action Check to see if PWR CONT line is less than 1 Vdc Low pressure in the KAC 1052. See Note 2 in Table 1002 KAC 1052 Pressure Indication (Task 23-10-07-99A-809-A01)). PS Interface Board is defective or PWR CONT line is not low. Sensor Board is defective or antenna connection is bad. Defective Coil, Shunt Cap or Series Cap Board. Defective Coil, Shunt Cap or Series Cap Board.
Alternate Cause/Action Defective PS Interface Board or CPU Board CPU Board is defective.
Pressure Fail or Pressure Warning annunciation on the controller
CPLR Fail annunciation on the controller Coupler fails to find a tune on any frequency Coupler fails to find a tune on a narrow band of frequencies Coupler finds a tune, but then retunes when making a transmission. Less than 6 dB of drop when bridging amplifier is disengaged
CPU Board is defective.
Defective Coil, Shunt Cap or Series Cap Board. Sensor Board is defective.
A loose connection exists or arching is occurring at the HN connector, feedline or antenna simulator. KAC 1052 has previously been tuned to this frequency or a nearby frequency.
Sensor Board is defective.
Table 1001 KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01)
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Pressure Indication No warning or failure indication Pressure Warning
Meaning Normal condition. Pressure is greater than 8 pounds per square inch (psi). The pressure has been reduced below 8 psi. No performance degradation will be observed. Continued operation may result in a pressure failure. The pressure has been reduced to a level at which arching could occur inside the antenna coupler at a 200 W power level. The system will automatically reduce the power to 50 W, regardless of the power level setting selected by the pilot.
Corrective Action Check pressure on an annual basis (See Note 1). Service the KAC 1052 in the near future to check for leaks and repressurize the unit.
Pressure Fail
Service the KAC 1052 immediately. Performance is reduced in this failure mode.
Note 1: When measured at room temperature, the pressure should be between 8 and 10 psi (66-69 kPa gauge). If below 8 psi, add Nitrogen to bring the pressure up to 8 to 10 psi. Note 2: With the KAC 1052 vented to the atmosphere at standard sea-level pressure, a Pressure Warning will be realized. A Pressure Fail will occur only at pressures below standard sea-level pressure. Table 1002 KAC 1052 Pressure Indication (Task 23-10-07-99A-809-A01)
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B. Bench-Test Harness Return to Service Test Solution (Subtask 23-10-07-75-001-A01) (1) Equipment Required The following equipment is required for manually bench testing the KAC 1052: 28 Vdc power supply capable of 30 A Multimeter 50 Ohm load (30 dB attenuator) with a 100 W minimum power rating Low-power 30 dB attenuator (1.2 W minimum) Antenna simulator - or 4 each 50 Ohm, 25 W loads. (See Paragraph 3.B.(2) Preliminary Setup for load configuration). SWR/Wattmeter capable of average reading and peak reading functions, 2-30 MHz. KHF 1050 System bench-test harness. Figure 9002 KHF 1050 System Bench-Test Harness (Task 23-10-06-99B-816-A01). Functional KPA 1052, KRX 1053 and controller
(2) Preliminary Setup Connect the KAC 1052 to a functioning KPA 1052, KRX 1053 and an ARINC 429 controller such as the PS440. Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01) for a suitable bench-test setup. If an antenna simulator representative of the antenna type used on the aircraft is available, connect the simulator to J10528. As an alternative, the following can be used. Honeywell KTS 157 Antenna Simulator 4 each 50 Ohm, 25 W loads; connected in parallel with short interconnects; then connected to the KAC 1052 with approximately 10 feet (3 m) of 50 Ohm coax (RG 214, or equivalent).
Set the power supply to between 27.5 and 28.0 Vdc (3) Antenna Coupler Tuning Tests (a) Perform Preliminary Setup per Paragraph 3.B.(2) Preliminary Setup in this section. Ensure that J10528 is terminated into an appropriate antenna simulator. (b) Turn the KHF 1050 system on and set the frequency to 2.1 MHz, AM mode. If a KTS 157 Antenna Simulator is being used, set the switch to position 1.
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Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01) (c) Momentarily key the transmitter with the PTT switch. The antenna coupler will begin the tuning sequence. During the tuning sequence, relay switching sounds will be heard inside the KAC 1052. The controller will also indicate that the antenna coupler is in the tuning process. Note: If the antenna coupler has already been tuned up into this load at this operating frequency (or into a load of similar impedance), the antenna coupler will not retune. If this is the case, skip to step (f).
(d) Observe the power on the Wattmeter in the AVERAGE reading mode. This will typically be 10 to 20 W, with up to 50 W possible.
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(e) As the antenna coupler is tuning, observe that the SWR reading is 2:1 or less. It is normal for the SWR to vary as the antenna coupler tunes the load. (f) After the tuning sequence has completed, key the microphone with no modulation and observe the SWR. The SWR should be less than or equal to 2.5:1. (On most frequencies, the SWR will be 1.5:1 or less.) Measured SWR at 2.1 MHz: __________ Note: If using a KTS 157 antenna simulator, limit the transmissions to a 25% duty cycle to prevent overheating the antenna simulator. Limit maximum transmission time to 20 seconds. The length of time it takes to tune the antenna will vary with operating frequency and antenna impedance. Tuning times of 1 to 30 seconds may be observed. Differences in SWR meter and wattmeter calibration may result in SWR and power readings somewhat different from those specified.
Note:
Note:
(g) Briefly speak into the microphone, and ensure that the SWR remains constant. (h) When not speaking, observe that unmodulated AM power is typically 50 W. Measured power at 2.1 MHz: __________. (i) Change the operating frequency to 10.1000 MHz. Repeat steps (c) through (h). (If using a KTS 157 Antenna Simulator, set the switch to position 3.) (j) Change the operating frequency to 29.9 MHz. Repeat steps (c) through (h). (If using a KTS 157 Antenna Simulator, set the switch to position 8.) (k) Change the operating frequency to any other desired test frequency. Repeat steps (c) through (h). (l) Return to an operating frequency of 2.1 MHz. (If using a KTS 157 Antenna Simulator, set the switch to position 1.) (m)Key the microphone. The KAC 1052 should not retune this time. The SWR and power should be the same as, or similar to, that noted in steps (f) and (h) at 2.1 MHz.
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(4) High-SWR Retune Test (a) Perform the Preliminary Setup in Paragraph 3.B.(2) Preliminary Setup and Antenna Coupler Tuning Tests in Paragraph 3.B.(3) Antenna Coupler Tuning Tests in this section. (b) Remove the KAC 1052 RF output, J10528, from the antenna simulator and connect J10528 to the 50 Ohm dummy load. (c) Set the frequency to 2.1 MHz, AM mode. (d) Momentarily key the transmitter with the PTT switch. The antenna coupler should sense that the load has changed and again begin its tuning sequence. During the tuning sequence, relay switching sounds will be heard inside the KAC 1052. The controller will also indicate that the antenna coupler is in the tuning process. NOTE: With some particular load impedance and frequency combinations, it is possible that the SWR will not exceed approximately 3:1 when changing from the antenna simulator to the 50 load. Under such conditions, a retune will not occur. (e) After the tuning sequence has completed, key the microphone with no modulation and observe that the SWR is less than or equal to 2.5:1. (5) Bridging Amplifier (a) Connect the equipment as shown in the Bridging Amplifier Test Setup, Figure 1001 KAC 1052 Test Setup (Task 23-10-07-99B-812-A01). Ensure that there is 60 dB of attenuation between KAC 1052 J10528 and the RF signal generator output. (b) Turn the KHF 1050 system on and set the frequency to one that the KAC 1052 has not been previously tuned up on, such as 10.200 MHz, USB voice mode. (This activates the bridging amplifier in the KAC 1052). (c) Tune the RF signal generator to 10.201 MHz with no modulation. Set the level to 60 dBm (d) Monitor the Receiver/Sidetone audio level on a distortion analyzer or an oscilloscope with the volume control set to mid range. Measured Level: __________________ VAC.
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Figure 1002 KAC 1052 Bridging Amplifier Test Setup (Task 23-10-07-99B-813-A01) (e) Momentarily key the PTT switch to tune the KAC 1052 into the attenuator. This deactivates the bridging amplifier. (f) When the KAC 1052 has completed the tuning, note the Receiver/Sidetone audio level. Measured Level: __________________ VAC.
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(g) The level in step (f) should be at least 6 dB lower (one-half the voltage or less) than that noted in step (d). Note: If the Bridging Amplifier Test is repeated, it is important to select a frequency that has not previously been tuned by the KAC 1052 in order to activate the bridging amplifier. Change the frequency at least 100 kHz from any previously tuned frequency.
C. KPA 1052 Adjustments The KAC 1052 does not contain any field adjustments. All adjustments are to be made in the factory. 4. Automatic Test Requirements (Task 23-10-07-75-803-A01) A. General (Subtask 23-10-07-75-004-A01) (1) This section contains information pertaining to the automated test solution for the KAC 1052 Coupler. B. Equipment and Materials (Subtask 23-10-07-75-005-A01) (1) Equipment and materials required to functionally test the KAC 1052 on the HF ATE System are contained in the following: HF ATE System, Part No. 071-05558-0001 KAC 1052 Test Sequence Software, Part No. 731-00804-XXXX
C. HF ATE System Test Solution (Subtask 23-10-07-75-006-A01) (1) HF ATE System Test Procedures (a) Attach the HF ATE System test cable connector marked J10521 to the INT connector (J10521) of the KAC 1052 to be tested. (b) Connect the HF ATE System test cable connector marked J10522 to the Control Connector (J10522) of the KAC 1052 to be tested. (c) Connect the HN output of the KAC 1052 to the HF ATE Antenna Simulator. (d) Apply power to the HF ATE System. (e) Execute the KAC 1052 Test Sequence Software.
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(f Following on screen instructions, enter operator name and password and UUT serial number. (g) After the test sequence screen opens, select the option TEST UUT. (h) Return to service testing will automatically execute.
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SCHEMATICS AND WIRING DIAGRAMS

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DISASSEMBLY
1. Task (Task 23-10-07-99C-803-A01) A. General (subtask 23-10-07-99F-006-A01) (1) Use these procedures to remove parts from the KAC 1052 to do the cleaning, checks, repair, and replacement of parts as necessary. References to the ILLUSTRATED PARTS LIST (IPL) show you where to find the parts to remove. The applicable figure number in the IPL is given in each primary paragraph and does not change until specified differently. (2) Before disassembly, use TESTING AND FAULT ISOLATION to examine the condition of the KAC 1052 or to find the most probable cause of malfunctions. Do this to prevent disassembly that is not necessary. Do only those procedures of disassembly that are necessary to remove defective parts and to correct malfunctions. (3) As an aid for assembly, tag the items that are disconnected to show where the connections were made. Include data on any special conditions of a connection such as the polarity and the position of the items. 2. Equipment and Materials (Task 23-10-07-94-802-A01) A. General (Subtask 23-10-07-94-002-A01) (1) Common shop tools and best-established shop practices are used to disassemble the KAC 1052. Refer to Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) to aid in disassembly. 3. Procedure (Task 23-10-07-03-801-A01) A. General (Subtask 23-10-07-03-001-A01) CAUTION: THE KAC 1052 HAS COMPONENTS THAT ELECTROSTATIC DISCHARGE MAY DAMAGE. REFER TO THE INSTRUCTIONS IN THE REPAIR CHAPTER WHEN YOU MOVE OR DISASSEMBLE THE KAC 1052. CAUTION: THE KAC 1052 IS A PRESSURIZED UNIT. BEFORE DISASSEMBLY RELIEVE THE PRESSURE BY DEPRESSING THE SCHRADER VALVE (12). FINISH RELIEVING THE PRESSURE BY REMOVING VENT PLUG (13).
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Arrange all subassemblies and the associated hardware in specific areas to aid in reassembly. (1) Side Plates (2) MPBC36547A Remove both side plates by removing 76 NA3x16Sus Screws (50). Carefully pop the side plates up and away from the chassis (1) to prevent rupturing the O-ring seals. (36) (2) Series Cap Board (26) MDLW11386D Remove the series cap board (CSC-591B) by removing the 8 NC3x10BS screws (57) securing the series cap board to the chassis (1). Slide the series cap board to the rear disconnecting it from the sensor and relay drive board (24). Remove the series cap board from the chassis (1). (3) Shunt Cap Board (25) MDLW11385F Remove the Shunt Cap Board (CSC-590B) by removing NC3x10BS screws (57) securing the Shunt Cap B board to the chassis (1). Remove the short standoff (near the unit HN connector) from the Shunt Cap Board. Remove the long standoff (near the long resistor on the rear of the board), which goes through the Shunt Cap Board, from the Coil Board. If provided, remove the long standoff near the lower front of the board, which goes through the Shunt Cap Board, from the Coil Board. (Early production units will not have this standoff.) Remove the W2 antenna wire (58) NC3x6Bs from the Shunt Board, freeing the board from the antenna wire. Slide the Shunt Cap Board to the rear, disconnecting it from the Sensor and Relay Drive Board (24) and lift it up and out of the chassis (1). (4) Coil Board (27) MDLW11390E Remove the coil board (CSC-592B) from the left side of the unit by removing 9 NC3x10BS screws (57) securing the board to the chassis. If the Series Cap Board and Shunt Cap Board have not been removed, remove three additional NC3x10BS screws attaching the Coil Board to the standoffs. (Early production units have only two standoff screws.) Slide the coil board to the rear, disconnecting it from the Sensor and Relay Drive board (24), and lift it up and out of the chassis (1).
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(5) Sensor and Relay Drive Board (24) MDCW10907D Remove the sensor and relay drive board (CNN-338) by removing the 4 NC3x6BS screws (58) securing the board to the standoffs (34) of the coupler control board (23). Remove the sensor relay board board by separating the bayonet pins from the CPLR control board connector. Remove the sensor and relay drive board from the chassis (1). (6) Shields (29) MPSC30332A Remove the 4 standoffs (34) securing the Shields to the CPLR control board (23). Dislodge the RF Collar from the BNC housing which will allow the shields to be removed as an assembly. (7) CPLR Control Board (23) MDLW11428 Remove the CPLR control board (CDC-1083B) by removing the 4 Shield standoffs (33). Remove the CPLR control board by separating the bayonet pins from the power supply and interface connector. Remove the CPLR control board from the chassis. (8) Power Supply and Interface Board (22) MDBW10546B Remove the PS and Interface board (CBL-103) by removing the 4 standoffs (32) securing the PS and Interface board to the front of the chassis (1) and 1 NC3x6Bs screw (58) from TP4 . Remove 8 S3x8 Sus screws (55) from J10521 and J10522 securing the connectors to the front of the chassis (1). Remove the PS and Interface board from the chassis (1) ensuring that the gaskets (15) & (16) do not tear as they will need to hold pressure upon reassembly.
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COMPONENT MAINTENANCE MANUAL KAC 1052 Coupler / Part No. 064-01074-0101
CLEANING
1. Task (Task 23-10-06-99C-804-A01) A. General (Subtask 23-10-06-99F-007-A01) (1) This section contains information pertaining to the cleaning of subassemblies in the KAC 1052. WARNING: GOGGLES MUST BE WORN WHEN USING PRESSURIZED AIR TO BLOW DUST AND DIRT FROM EQUIPMENT. ALL PERSONNEL SHOULD BE CLEARED FROM THE IMMEDIATE AREA. WARNING: OPERATIONS INVOLVING THE USE OF A CLEANING SOLVENT SHOULD BE PERFORMED UNDER A VENTILATED HOOD. AVOID BREATHING SOLVENT VAPOR AND FUMES. AVOID CONTINUOUS CONTACT WITH THE SOLVENT. 2. Equipment and Materials (Task 23-10-06-94-803-A01) A. General (Subtask 23-10-06-94-003-A01) (1) Table 4001 Recommended Cleaning Materials (Task 23-10-07-99A-810-A01) lists the recommended cleaning agents to be used during overhaul of the KAC 1052. NOTE: Equivalent substitutes may be used as cleaning agents. (2) In this section, air jet refers to a hand-operated air nozzle supplied with clean, dry, compressed air at a maximum of 28 pounds of force per square inch (psi).
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Type Denatured Alcohol Isopropyl Alcohol Lintless Tissue Cloth, Lint-Free Cotton Brush, Flat Brush, Round
Used to Clean / Description Exterior Surfaces Interior Surfaces Kimberly-Clark Kimwipes ( or equivalent) Various Various, fiber bristles Various, fiber bristles
Table 4001 Recommended Cleaning Materials (Task 23-10-07-99A-810-A01) 3. Procedure (Task 23-10-06-16-801-A01) A. General (Subtask 23-10-06-16-001-A01) WARNING: THE KAC 1052 HAS COMPONENTS THAT ELECTROSTATIC DISCHARGE MAY DAMAGE. REFER TO THE INSTRUCTIONS IN THE REPAIR CHAPTER WHEN YOU MOVE OR DISASSEMBLE THE KAC 1052. (1) Exterior Surfaces (a) Wipe exterior of the KAC 1052 with a lint-free cloth dampened with denatured alcohol. (b) If necessary, open any blocked ventilation holes by first saturating the debris clogging the apertures with denatured alcohol and then blowing the loosened material out with an air jet. (c) Clean connectors as outlined in Paragraph 3.A.(2) Cleaning Connectors. (2) Cleaning Connectors CAUTION: DO NOT PERMIT SOLVENT TO RUN INTO SLEEVES OR CONDUIT THAT COVERS WIRES CONNECTED TO INSERT TERMINALS. (a) Wipe dust and dirt from bodies
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(b) Wipe parts dry with a clean, dry, lint-free cloth. (c) Remove dirt and lubricant from the connector inserts, insulation and terminals, using a small soft-bristled brush moistened with solvent. (d) Dry the inserts with an air jet. (3) Modules CAUTION: HONEYWELL RECOMMENDS ISOPROPYL ALCOHOL AS A SAFE CLEANING SOLVENT FOR PRINTED CIRCUIT BOARDS CONTAINING ALUMINUM ELECTROLYTIC CAPACITORS. SOLVENTS WHICH MAY BE USED ARE AS FOLLOWS: SAFE SOLVENTS Isopropyl Alcohol Methyl Alcohol Butyl Alcohol Propyl Alcohol Ethyl Alcohol Calgonite (Detergent) Xylene CAUTION: PRINTED CIRCUIT BOARDS CONTAINING ALUMINUM ELECTROLYTIC CAPACITORS SHALL NOT BE CLEANED WITH THE FOLLOWING SOLVENTS: UNSAFE SOLVENTS Freon TF, TMC Trichloroethane Carbon Tetrachloride ALL (Detergent) Chloroform Methylene Chloride Trichloroethylene CAUTION: ULTRASONIC CLEANING CAN DAMAGE CERTAIN PARTS AND SHOULD GENERALLY BE AVOIDED.
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(a) Modules containing resistor, capacitors, inductors, transformers and other wired parts should be cleaned as follows: (1) With a soft-bristled brush and an air jet, remove large dust and dirt particles from all surfaces, including parts and wiring. (2) Any dirt or dust that cannot be removed in this manner should be removed with a brush (not synthetic bristle) saturated with an approved solvent. Remove any excess solvent with a clean, dry air jet. (3) Remove flux residue, metallic chips, or solder balls with the approved solvent. NOTE: Solvents may be physically applied in several ways, such as agitation, spraying, brushing and vapor degreasing. The cleaning solvents and methods used should have no deleterious effect on the parts, connections and materials being used. (b) If sensitive components are being used, spray is recommended. Uniformity of solvent spray flow should be maximized and wait time between soldering and cleaning should be minimized. (4) Chassis, wired CAUTION: AVOID AIR BLASTING SMALL COILS, LEADS AND OTHER DELICATE PARTS BY HOLDING AIR JET NOZZLE TOO CLOSE. USE BRUSHES CAREFULLY ON DELICATE PARTS. NOTE: When necessary to disturb dress of wiring and cables, note the positions before disturbing and restore to proper dress after cleaning. (a) Clean chassis containing terminal boards, resistor and capacitor assemblies, RF coils, switches, sockets, inductors, transformers and other wire parts as follows: (1) Clean printed circuit boards (modules) as outlined in Paragraph 3.A.(3) Modules. (2) Blow dust from surface, holes and recesses using an air jet. (3) With minimum disturbance to wiring, clean connectors as outlined in Paragraph 3.A.(2) Cleaning Connectors
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(4) Finish cleaning chassis by wiping finished surfaces with a lint-free cloth moistened with solvent. (5) Dry with a clean, dry, lint-free cloth. (6) When thoroughly clean, touch up any minor damage to finish. (7) Protect chassis from dust, moisture and damage pending inspection. (5) Covers (a) Side covers and chassis should be cleaned as follows: (1) Remove surface grease with a lint-free cloth. (2) Blow dust from surface, holes and recesses using an air jet. (3) If necessary, scrub with a solvent until clean. Work over all surfaces and into all holes and recesses with a suitable nonmetallic brush. (4) Position the cleaned part to dry so solvent is not trapped in holes or recesses. Use an air jet to blow out any trapped solvent. (5) When thoroughly clean, touch up any minor damage to the finish.
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CHECK
1. Task (Task 23-10-07-99C-805-A01) A. General (Subtask 23-10-07-99F-008-A01) (1) Perform checks of the KAC 1052 Coupler to determine the condition of its physical, mechanical, and electrical properties. These properties are compared to established standards. (2) Visual checks make sure the parts of the KAC 1052 are serviceable and show no signs of wear, damage, or possible failure. (3) During disassembly, assembly or repair, use Paragraph 3. Procedure (Task 23-10-07-21-801-A01) to find the condition of the KAC 1052. 2. Equipment and Materials (Task 23-10-07-94-804-A01) A. General (Subtask 23-10-07-94-004-A01) (1) Common shop tools and best established shop practices are used to perform the checks in this subheading. 3. Procedure (Task 23-10-07-21-801-A01) A. General (Subtask 23-10-07-21-001-A01) (1) Structural Checks (a) Make sure the KAC 1052 is clean and has no dirt, chips, solder splashes, or other unwanted materials such as excess grease or oil. The component leads must be free from grease, dirt, paint, mold flash, and other contaminants. (b) Make sure all parts are installed or attached correctly. Check for damaged, loose, or missing parts. (c) Check for bent or damaged connector pins. (d) Check threads on applicable parts for burrs or cross-threads (connectors, frames, and heat sink brackets, etc.). (e) Check the metal parts for corrosion, rust, or other structural damage.
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(f) Check that no pinholes, pits, or other voids are found at joints and connection points or where circuit lines change direction abruptly. (2) Electrical Checks (a) Check that solder is properly applied and connections are secure. Solder joints must be tight and free from scratches, roughness, sharp edges, dullness, bridging, or blistering. Solder joints must show evidence of wetting (molten solder adhering and flowing on a metallic surface to a smooth, even coating) and bonding where the solder blends to the soldered surface forming a small contact angle. (b) Check for signs of arcing, especially around the HN connector (J10528) and the Coil Board, Shunt Cap Board and Series Cap Board. (c) Check the electrical components for cracks, corrosion, discoloration, or burned, overheated areas. (d) Check for heat or solvent damaged to components and markings. (e) Check for broken or disconnected bus wires. Bus wires found in this condition must be replaced. (f) Check leadwires for breaks or brittleness.
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REPAIR
1. Task (Task 23-10-06-99C-806-A01) A. General (Subtask 23-10-06-99F-009-A01) (1) Use these procedures to correct problems that are identified during the procedures in CHECK and TESTING AND FAULT ISOLATION. Repair of the KAC 1052 is done to replace or repair subassemblies, to replace defective parts and wires and to correctly attach loose wires. Repair of the subassemblies is usually done to replace defective parts. (2) Refer to ASSEMBLY and DISASSEMBLY for removal and installation instructions. Do only those procedures of disassembly that are necessary to make repairs. When new parts are necessary, refer to the ILLUSTRATED PARTS LIST for the correct part numbers, quantities and hardware that is attached. 2. Equipment and Material (Task 23-10-06-94-805-A01) A. General (Subtask 23-10-06-94-005-A01) WARNING: BEFORE YOU USE A MATERIAL, REFER TO THE MANUFACTURERS MATERIAL SAFETY DATA SHEETS FOR DATA ON PERSONAL PROTECTION. SOME MATERIAL CAN BE DANGEROUS. (1) Crocus cloth, grade 4/0 - optional source (2) Isopropyl alcohol (99%) - optional source NOTE: Equivalent alternatives are permitted for equipment and materials in this list. 3. Procedure (Task 23-10-06-35-801-A01) A. General (Subtask 23-10-06-35-001-A01) CAUTION: THIS EQUIPMENT IS SENSITIVE TO DAMAGE BY ELECTROSTATIC DISCHARGE. THIS EQUIPMENT CONTAINS MOISTURE SENSITIVE PARTS. SPECIAL PROCEDURES ARE REQUIRED
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(1) General Repair Procedures (a) Straighten warped or bent cover surface. (b) Straighten any bent pins in connectors. (c) Replace screws, nuts and bolts that are stripped or have other damage. NOTE: Before you repair electrical connections, note the color code and routing of lead wires. Use the lead wire you removed to measure for replacement. (d) Repair defective wiring. (2) Detailed Repair Procedures (a) Replace broken or disconnected wires. (b) Replace damaged or defective switches.
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ASSEMBLY
1. Task (Task 23-10-07-99C-807-A01) A. General (Subtask 23-10-07-99F-010-A01) (1) This section provides information for assembly of the KAC 1052. The assembly procedure is to be followed after the unit has been disassembled for repair, modification by a Service Bulletin, cleaning, or inspection. WARNING: REMOVE ALL POWER FROM THE UNIT BEFORE ASSEMBLY OF ANY MODULE. BESIDES BEING DANGEROUS TO LIFE, VOLTAGE TRANSIENTS CAN CAUSE CONSIDERABLE DAMAGE TO THE EQUIPMENT. CAUTION: EXERCISE EXTREME CARE WHEN RECONNECTING MULTI-PIN CONNECTORS. ENSURE THAT CONNECTORS ARE NOT DAMAGED BY MISALIGNMENT OF THE PINS. B. Staking Compounds, Sealants, Thermal Compounds, and Lubricants to be Used (Subtask 23-10-07-99F-011-A01) (1) Table 7001 Sealants, Staking Compounds, Thermal Compounds, and Lubricants (Task 23-10-07--99A-809-A01) lists the staking compounds, sealants, and thermal compounds to be applied during assembly. Points of application are referenced on the drawings in the ILLUSTRATED PARTS LIST(IPL). CAUTION: THREAD LOCKING SEALANTS MAY TEND TO SOFTEN OR CRAZE VINYL, CELLULOSIC, STYRENE, ABS, POLY CARBONATE, AND METHACRYLATE PLASTICS. NOTE: Equivalent substitutes may be used for sealants, staking compounds, thermal compounds, and lubricants listed in Table 7001 Sealants, Staking Compounds, Thermal Compounds, and Lubricants (Task 23-10-07--99A-809-A01).
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Place Used Screw Threads Side Plates
Representative Type Locktite 425 Dow Corning HV Grease
Honeywell Part Number 016-01412-0000 005-02133-0075
Qty Used (as required) (as required)
Table 7001 Sealants, Staking Compounds, Thermal Compounds, and Lubricants (Task 23-10-07--99A-809-A01) C. Screw and Nut Torque Values (Subtask 23-10-07-99F-012-A01) (1) Table 7002 Typical Screw and Nut Torque Values (Task 23-10-07-99A-810-A01) lists typical torque values to be observed when screws and nuts are tightened during assembly of the unit.
Table 7002 Typical Screw and Nut Torque Values (Task 23-10-07-99A-810-A01)
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2. Equipment and Materials (Task 23-10-07-94-806-A01) A General (Subtask 23-10-07-94-006-A01) (1) Common shop tools and best-established shop practices are used to assemble the KAC 1052. Refer to Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) to aid in assembly. 3. Procedure (Task 23-10-07-43-801-A01) A. General (Subtask 23-10-07-43-001-A01) CAUTION: THE KAC 1052 HAS COMPONENTS THAT ELECTROSTATIC DISCHARGE MAY DAMAGE. REFER TO THE INSTRUCTIONS IN THE REPAIR CHAPTER WHEN YOU MOVE OR DISASSEMBLE THE KAC 1052. CAUTION: ALL SEALING SURFACES MUST BE CLEAN OF ALL FOREIGN MATERIAL. NOTE: APPLY LOCKTITE 425 TO ALL SCREWS BEFORE INSERTION. Assembly of the KAC 1052 should be the reverse of disassembly but will include added precautions and requirements. These procedures will begin at complete disassembly and work toward total assembly. For any partial disassembly for repair, this procedure may be begin at the last board removed. (1) PS and Interface Board (22) MDBW10546B Apply grease (Dow Corning 3452) between the chassis assembly gaskets (15) and (16) and the Sub-D 37 pin (J10521) and Sub-D 9 pin (J10522) connectors. Insert the PS and Interface Board (CBL-103),. Secure by inserting 8 S3x8 Sus screws (55). Torque the screws to 6.5 0.1 in-lb. Repeat torquing screws (55) three times in sequence, or until screws no longer rotate when 6.5 +/- 0.1 in-lb is applied. Ensure that the 4 spacers (31) are in place and install the 4 standoffs (32) securing the board to the chassis (1). Install 1 NC3x6Bs screw (58) at TP4.
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(2) CPLR Control Board (23) MDLW11428 Carefully install the CPLR control board (CDC-1083B) into the chassis (1), aligning the bayonet pins with the connector on the PS and interface board (22). Squeeze the connector together assuring proper pin contact. Install the 4 standoffs (33) securing the board to the PS and Interface board. (3) Shield Assembly (29) MPSC30332A Install the shield assembly into the chassis (1). Press the RF Collar into the BNC housing . This is a pressure fit. ensure that it seated completely. Align the standoff and screw holes. When the shield cap (29) can not be inserted in the front panel, apply a lubricant. Install the 4 standoffs (34) to secure the shield assembly to the standoffs from the CPLR control board (23). (4) Sensor and Relay Drive Board (24) MDCW10907D Carefully install the Sensor and RLY DRV board (CNN-338) into the chassis, aligning the bayonet pins with the connector on the CPLR control board (23). Squeeze the connector together assuring proper pin contact. The sensor and relay drive board should be aligned with the 4 standoffs (34) from the shield assembly (29). Install 4 NC3x6BS screws (58) to secure the board to the shield assembly standoffs (34). (5) Coil Board (27) MDLW11390E Insert the Coil board (CSC-592B) into the chassis (1) on the left side, maintaining proper orientation to align the connector to the pins on the Sensor and RLY DRV board (24). Push the coil board forward seating the connector against the Sensor RLY DRV board (24). The chassis standoffs will now be aligned. Install 9 NC3x10BS screws (57) securing the board to the chassis (1). If the Coil Board was removed without removing the Series Cap Board and Shunt Cap Board, install three additional NC3x10BS screws attaching the Coil Board to the standoffs. (Early production units have only two standoff screws.)
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(6) Shunt Cap Board (25) MDLW11385F Insert the Shunt Cap board (CSC-590B) on the right side, maintaining proper orientation to align the connector to the pins on the Sensor RLY DRV board (24). Push the shunt cap board forward seating the connector against the Sensor RLY DRV board (24). The chassis standoffs are now aligned. Install 10 NC3x10BS screws (57) securing the shunt cap board to the chassis (1). Install one long standoff through the hole in the Shunt Cap Board near the long resistor on the rear of the board and attach it to the Coil Board (27) with 1 NC3x10BS screw (57). If provided, also install one long standoff through the hole in the Shunt Cap Board near the lower front of the board near the unit HN connector (P10528) and attach it to the Coil Board (27) with 1 NC3x10BS screw (57). Install the standoff on the shunt cap board near the unit HF connector (J10528). Attach the RF antenna wire to W2 by securing it with 1 NC3x6Bs screw (58). (7) Series Cap Board (26) MDLW11386D Install the Series cap board (CSC-591B) on the right side after the Shunt Cap Board (25), maintaining proper orientation to align the connector to the pins on the Sensor RLY DRV board (24). Push the series cap board forward seating the connector against the sensor RLY DRV board (24). All standoffs are now aligned. Install 8 NC3x10BS screws (57) securing the series cap board to the chassis (1). (8) Side Plates (2) MPBC36547A Clean and degrease sealing surfaces on chassis (1). Clean and degrease o-ring groove in side plate (2). Apply a thin uniform film of Dow Corning High Vacuum Grease to sealing surfaces on chassis (1) and o-ring groove in side plate (2). Place side plate (2) on a flat surface and place o-ring (8) in groove. Carefully lower chassis (1) onto side plate (2). Turn chassis/side plate (1/2) over, being careful not to allow side plate (2) to slip. (It is helpful to partially install two side plate screws () prior to turning assembly over.) Install the six side plate screws (50) shown in Figure 7001 Side Plate Installation (Task 23-10-07-99B-814-A01) and tighten them 1/2 to 1 turn at a time until all are fully seated. Install the remaining side plate screws (50) and torque to 4.7 +/0.5 in-lb. Repeat torquing all side plate screws (50) two times in sequence, or until screws no longer rotate when 4.7 +/- 0.5 in-lb is applied. Repeat this procedure for the other side plate (2).
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Figure 7001 Side Plate Installation (Task 23-10-07-99B-814-A01) B. Pressurization (Task 23-10-07-43-002-A01) (1) Pressurization with dry nitrogen. When assembly is complete, ensure that the Schrader valve (12) core is tightly seated in the charging valve. (a) Set the regulator on the dry nitrogen source to 15 PSI (103.43 kPa) and attach the filling hose to the charging valve. (b) Remove the vent plug (13) on the back of the unit, if installed. (c) Open the nitrogen tank valve to purge the air in the KAC 1052 tube. (d) After about 30 seconds, turn the nitrogen tank valve off. (e) Apply grease to the vent plug seal (13) and install. Torque to 3.7 .1 in-lb (do not overtighten and rupture the fiber washer ). (f) Set the regulator on the dry nitrogen source to 10 PSI. Recharge the unit with dry nitrogen to 9 .5 PSI. See Notes on Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01). (g) Apply grease to the Schrader valve cap and install. Torque to 5 0.5 in-lb.
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CAUTION: DO NOT OPERATE THE KAC 1052 IN AN AIRCRAFT WITHOUT CHARGING THE UNIT AND MAKING CERTAIN THERE ARE NO NITROGEN LEAKS. (2) Pressurization with dry air pump. CAUTION: PRESSURIZATION WITH A DRY AIR PUMP SHOULD ONLY BE DONE WHEN DRY NITROGEN IS NOT AVAILABLE. PURGING AND RE-PRESSURIZATION WITH NITROGEN SHOULD BE DONE AT THE EARLIEST OPPORTUNITY. (a) Remove the valve cap from the KAC 1052 charging valve. Make sure the valve core is tightly seated in the charging valve (12). Remove the vent plug (13). (b) Attach dry air pump to the charging valve and purge the air within the coupler by pumping for about 30 seconds. (c) Apply grease (Dow Corning 3452) to vent plug (13) and install . Torque to 3.7 .1 in-lb (do not overtighten and rupture the fiber washer ). (d) Using dry air pump, pressurize the coupler to 9 .5 PSI. (See notes on Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01)) (e) After re-pressurization has been performed, the final test procedure should be accomplished before returning the unit to service.
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COMPONENT MAINTENANCE MANUAL KAC 1052 Antenna Coupler / Part No. 064-01074-0000.
FITS AND CLEARANCES

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COMPONENT MAINTENANCE MANUAL KAC 1052 Antenna Coupler / Part No. 064-01074-0000.
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SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1. Task (Task 23-10-06-99C-808-A01) A. General (Subtask 23-10-06-99F-011-A01) (1) This section contains the special tools, fixtures, and equipment necessary to support the KPA 1052 in a maintenance facility. 2. Return to Service Testing (Task 23-10-06-94-807-A01) A. General (Subtask 23-10-06-94-007-A01) (1) The KPA 1052 may be tested as a stand-alone unit with a properly configured HF ATE (Automated Test Equipment) System or as part of a KHF 1050 system using a bench-test harness. Refer to Paragraph 3.B. Bench-Test Harness Return to Service Test Solution (Subtask 23-10-07-75-001-A01) in TESTING AND FAULT ISOLATION for the bench-test harness procedure, and to Paragraph 4.C. HF ATE System Test Solution (Subtask 23-10-07-75-006-A01) in TESTING AND FAULT ISOLATION for the ATE System procedure. (2) The following special tools, fixtures, and equipment are required to functionally test the KPA 1052 using Automated Test Equipment (ATE). HF ATE System - P/N 071-05558-0001 See Figure 9001 HF ATE System (Task 23-10-06-99B-815-A01). KHF 1050 System Bench-Test Harness See Figure 9002 KHF 1050 System Bench-Test Harness (Task 23-10-06-99B-816-A01).
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Figure 9001 HF ATE System (Task 23-10-06-99B-815-A01)

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Figure 9002 KHF 1050 System Bench-Test Harness (Task 23-10-06-99B-816-A01)

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SPECIAL PROCEDURES
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REMOVAL
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INSTALLATION
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SERVICING
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STORAGE (INCLUDING TRANSPORTATION)

1. Storage (Task 23-10-06-55-801-A01) A. Storage After Assembly (Subtask 23-10-06-55-001-A01) (1) If units are to be stored for 7 days or less, perform the Short-Term Storage procedures of Paragraph 1.A.(2) Short-Term Storage. If units are to be stored for up to 6 months, perform the Temporary Storage procedures of Paragraph 1.A.(3) Temporary Storage. If it is anticipated that units will be stored for longer than 6 months, perform the procedures of Paragraph 1.A.(4) Extended Storage. (2) Short-Term Storage (a) Store away from vibration and shock. (b) Storage temperature range shall not exceed -55 to +85C (-67 to +185F). (3) Temporary Storage (a) Place equipment in a waterproof plastic bag. (b) Put a packet of silica gel or other desiccant in the bag. (c) Seal open end of plastic bag. (d) Store away from vibration and shock. (e) Storage temperature range shall not exceed -55 to +70C (-67 to +158F). (4) Extended Storage (a) Place the unit in a waterproof plastic bag. (b) Put a packet of silica gel or other desiccant in the bag. (c) Seal open end of plastic bag. (d) Store away from vibration and shock. (e) Storage temperature range shall not exceed -55 to +70C (-67 to +158F). Humidity shall not exceed 95 percent (%), noncondensing.
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COMPONENT MAINTENANCE MANUAL KAC 1052 Antenna Coupler / Part No. 064-01074-0000. 0001, 0101
REWORK
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ILLUSTRATED PARTS LIST

1. Introduction (Task 23-10-07-99C-809-A01) A. General (Subtask 23-10-07-99F-014-A01) This Illustrated Parts List is a complete list of assemblies and parts for the KAC 1052 Antenna Coupler. Reference Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01) and Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01). Periodically the Illustrated Parts List is revised to cover additions, deletions, or changes to the equipment. These revisions are indicated by an R placed to the right of each revised line and apply to the current revision only. B. Parts Listing (Subtask 23-10-07-99F-015-A01) (1) FIND NO. Column This column lists the find number as shown in the assembly drawing. (2) PART NUMBER Column In this column are listed Honeywell part numbers for each part and assembly. (3) DESCRIPTION Column This column identifies each part and assembly by verbal description. (4) QTY Column The total quantity of parts or assemblies required at each location is listed in this column.
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NUMERICAL INDEX
FIND NO. 1 2 4 5 7 8 12 13 15 16 17 18 19 20 22 23 24 25 26 27 29 31 32 33
PART NUMBER MPBC36866 MPBC36547A MTB364529 MTB364530 MPXL30173 MPPK30976 MPXL30174 MPTG31242 MPPK30974A MPPK30975A MTT309136 MTL316688 MTL316711 MPTG31273 MDBW10546B MDLW11428 MDCW10907D MDLW11385F MDLW11386D MDLW11390E MPSC30332A MTL316690 MTL316693 MTL316694
DESCRIPTION PRINTED CHASSIS ASSEMBLY SIDE PLAT ASSEMBLY FRONT BRACKET REAR BRACKET PRESSURE RELIEF VALVE O-RING AIR VALVE VENT PLUG GASKET 37 PIN GASKET 9 PIN GASKET GROUND STUD WASHER NUT SELF LOCKING PS & INTERFACE BOARD CPLR CONTROL BOARD SENSOR & RLY DRV BOARD SHUNT CAP BOARD SERIES CAP BOARD COIL BOARD SHIELD SPACER-1 STANDOFF-5 STANDOFF-6
QTY 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4
Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01) (sheet 1 of 2)

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FIND NO. 34 35 36 37 38 39 40 41 42 44 45 46 47 48 49 50 51 52 53 54 55 57 58 59
PART NUMBER MTL316695 MPNN40129 MPPK30920 MTT308482A MPNN40379A MPNN39853 MPNN39854A MPNN39856 MPNN39857 MPNN40026 BSPT01253C BSPT02033C BSPT05503C MPNN40639 MPTG31330 BRTG03582 BRTG03577 MPTG31300 BRTG01619 BRTG00345 BRTG00531 BSNC03010B BSNC03006B BSSW03000S STANDOFF-7
DESCRIPTION
QTY 4 1 2 1 2 1 1 1 1 1 1 1 1 1 2 76 16 1 2 1 8 28 6 14
DISCERNMENT LABEL O-RING COVER WARNING LABEL NAME PLATE S/N TAG DECAL, CAUTION DECAL WARRANTY SEAL SOFTWARE MOD. TAG CRIMP-STYLE TERMINAL R1.25-3 CRIMP-STYLE TERMINAL 2-S3.3 CRIMP-STYLE TERMINAL 5.5-S3 LABEL CAPTIVE PANEL SCREW SCREW ASSY. NA3X16SUS SCREW ASSY. NA3X8SUS HEX. NUT NO.6-32UNC BS WASHER M3.5BS SPRING LOCK WASHER SW3.5 SCREW S3X8SUS SCREW ASSY. NC3X10BS SCREW ASSY. NC3X6BS SPRING LOCK WASHER SW3
Table 10001 KAC 1052 Coupler (Task 23-10-07-99A-811-A01) (sheet 2 of 2)
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Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) (Sheet 1 of 2)

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Figure 10001 KAC 1052 Final Assembly (Task 23-10-07-99B-816-A01) (sheet 2 of 2)

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Kac-1052 - Maintenance Manual 006-15640-0001 - 1

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COMPONENT MAINTENANCE MANUAL

KAC 1052 Antenna Coupler

MANUAL NUMBER 006-15640-0001 REVISION 1 JANUARY, 2004

Component Maintenance Manual with illustrated parts list

KAC 1052 Antenna Coupler

RECORD OF TEMPORARY REVISIONS

Temp Rev. No.

SERVICE BULLETIN LIST

Manual Revision Number

Manual Revision Date

LIST OF EFFECTIVE PAGES

indicates a changed, added, or deleted page

LIST OF EFFECTIVE PAGES

indicates a changed, added, or deleted page

LIST OF EFFECTIVE PAGES

indicates a changed, added, or deleted page

LIST OF EFFECTIVE PAGES

indicates a changed, added, or deleted page

TABLE OF CONTENTS DESCRIPTON PAGE

TABLE OF CONTENTS (cont) DESCRIPTON PAGE

TABLE OF CONTENTS (cont) DESCRIPTON PAGE

TABLE OF CONTENTS (cont) DESCRIPTON PAGE

LIST OF FIGURES DESCRIPTION PAGE

LIST OF TABLES DESCRIPTION PAGE

B. Acronyms (Subtask 23-10-06-99F-002-A01)

Table INTRO-1. Acronyms (Task 23-10-07-99A-801-A01)

DESCRIPTION AND OPERATION

Figure 1 KAC 1052 Antenna Coupler (Task 23-10-07-99B-801-A01)

Altitude: Power Requirements: Connectors:

DESCRIPTION C31d, C32d, DO-160D Env. cat .

Table 2 KAC 1052 Subassemblies (Task 23-10-07-99A-804-A01)

Figure 2 KAC 1052 Subassembly Locations (Task 23-10-07-99B-802-A01)

Figure 4 Simplified Block Diagram (Task 23-10-07-99B-804-A01)

X = either relay on or off, depending on inductor value

Blank = relay open

Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01) (sheet 1 of 2)

X = either relay on or off, depending on inductor value

Blank = relay open

Table 3 Circuit Configurations (Task 23-10-07-99A-805-A01) (sheet 2 of 2)

Figure 8 Bridging Amplifier Block Diagram (Task 23-10-07-99B-808-A01)

Figure 9 CPLR Control Block Diagram (Task 23-10-07-99B-809-A01)

Figure 11 PS and Interface Surge Protection Circuits (Task 23-10-07-99B-811-A01)

Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01) (sheet 1 of 2)

Table 4 Interface Signal Description J10521 (Task 23-10-07-99A-806-A01) (sheet 2 of 2)

Source/Dest External PC External PC External PC External External N/A

I/O Output Input N/A Input Output N/A

Properties RS-232C RS-232C GND Low in active Analog Voltage GND

Table 5 Interface Signal Description J10522 (Task 23-10-07-99A-807-A01)

TESTING AND FAULT ISOLATION

Symptom Unit totally inoperative

Pressure Fail or Pressure Warning annunciation on the controller

CPU Board is defective.

Sensor Board is defective.

Table 1001 KAC 1052 Fault Isolation (Task 23-10-07-99A-808-A01)

Pressure Indication No warning or failure indication Pressure Warning

SCHEMATICS AND WIRING DIAGRAMS

Place Used Screw Threads Side Plates

Representative Type Locktite 425 Dow Corning HV Grease

Honeywell Part Number 016-01412-0000 005-02133-0075