Page 1 2101 I/O PLUS Receiver Display Unit Part No. 81440 V01105 COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST 34-51-04 15 MARCH 2009 Publishing Number 82912 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 2 2101 I/O Plus Display Components Maintenance Manual PROPRIETARY NOTICE This document and the information disclosed herein are proprietary data of FreeFlight Systems. Neither this document nor the information contained herein shall be used, reproduced, or disclosed to others without the written authorization of FreeFlight Systems, except to the extent required for installation or maintenance of recipient's equipment.
Page 3 Date Received READER COMMENTS Freeflight Systems welcomes all comments and recommendations to improve future editions of this publication. Your Name Company Airline Address State Country Telephone No. Date FreeFlight Pub. No. ATA No. Manual Title COMMENTS/RECOMMENDATIONS: LOCAL REPRODUCTION ENCOURAGED (If returning by mail, please tape closed; Postal regulations prohibit use of staples.)
Page 4 From: __________________________________________ ______________________________________ Place Stamp Here ______________________________________ ______________________________________ FreeFlight Systems Manager, Technical Publications Aerospace Division 3700 Interstate 35 S. Waco, TX 76706 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 5 REPORT OF POSSIBLE DATA ERROR Your Name Company Airline Address State Country Telephone No. Date FreeFlight Pub. No. ATA No. Manual Title PAGE NO. PARA GRAPH FIGURE NO. TABLE NO. PROBLEM FREEFLIGHT REPLY: APPROVAL: LOCAL REPRODUCTION ENCOURAGED (If returning by mail, please tape closed; Postal regulations prohibit use of staples.)
Page 6 From: __________________________________________ ______________________________________ Place Stamp Here ______________________________________ ______________________________________ FreeFlight Systems Manager, Technical Publications Aerospace Division 3700 Interstate 35 S. Waco, TX 76706 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 7 2101 I/O Plus Display Components Maintenance Manual MATERIALS HAZARD RATING CODE This manual uses the National Fire Protection Association system to identify the different levels of hazards caused by the use of a given material. A Hazard Code identifies three effects of a material on a person: health (eat, drink, touch, and breathe), fire (when and how it burns), and reactivity (chemical explosions).
Page 8 2101 I/O Plus Display Components Maintenance Manual HEALTH HAZARD RATING IN POSITION 1 Rating Description Effect of Exposure Very bad health Very short exposures could cause DEATH or CRITICAL hazard REMAINING INJURY even after fast medical treatment. Do not breathe the vapor or come in contact with the liquid without approved protection.
Page 9 2101 I/O Plus Display Components Maintenance Manual RECORD OF REVISIONS Assigned To (Job Title) Location Revision Insertion Revision Insertion Date Date Date Date Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page RR-1 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 10 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 11 2101 I/O Plus Display Components Maintenance Manual RECORD OF TEMPORARY REVISIONS Assigned To (Job Title) Location Temporary Date Date Date Revision No. Revised Inserted Removed Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page RTR-1 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 12 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 13 2101 I/O Plus Display Components Maintenance Manual SERVICE BULLETIN LIST FOR PART NO. 81440 Service Identified Date Included Bulletin in this Manual Description Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page SBL-1 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 14 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 15 2101 I/O Approach Plus GPS Navigation Systems, Part Numbers 81440-02-XXXX, 81440- 03-XXXX, 81440-12-XXXX, 81440-32-XXXX, 81440-33-XXXX, and 81440-42-XXXX. Release of operating system –241L. SUMMARY: FreeFlight Systems has released software system –241L for the 2101 I/O Plus. PLANNING INFORMATION Effectivity This Service Bulletin applies to the 2101 I/O Approach Plus GPS Navigators, Part...
Page 16 I. Other Publications Affected 84923, Rev A FreeFlight 2101 I/O Approach Plus Pilot Guide Supplement 84929, Rev A FreeFlight 2101 I/O Approach Plus GPS Receiver Installation and Checkout Manual Supplement J. Interchangeability and Identification Modified and unmodified units are not interchangeable.
Page 17 (15) working days after receipt of the unit, depending upon parts availability. Level II Service Centers wishing to incorporate Service Bulletin 81440-XX-00-21 should issue a purchase order to FreeFlight for the number of Service Bulletin kits required. Parts List...
Page 18 3700 Interstate 35 S. Telephone 1 (254) 662-0000 Waco, TX 76706 USA Fax 1 (254) 662-9451 For FreeFlight Factory Service Center modification, send the Navigator and a purchase order requesting incorporation of Service Bulletin 81440-XX-00-21 to: FreeFlight Systems Attn.: Repair Dept.
Page 19 Database Card Insert the flash card into the memory card slot on the front of the unit. Turn power ON to the 2101 I/O Plus. The unit will begin its startup procedure. Verify that the following message is displayed: FLASH CARD DETECTED...
Page 20 Verify that the software version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. Press NAV. The following message will appear. GPS: 5.05B B72AA2D5 PUSH NAV TO CONTINUE Verify that the Software Version and CRC on the top line of the display match the above text.
Page 21 After the image verification is complete, the unit will reset. Then it will display this message: PERFORMING BUILT IN TEST CLEAR BATTERY BACKED MEMORY SUCCESSFUL FreeFlight 2101 I/O SAR SYSTEM CODE: 241L c2008 It is followed by: IOP ROM UPDATED OK PWR OFF, REMOVE CARD 17.
Page 22 IFR NOT ALLOWED 25. If any of the above messages appear, perform the software loading again. If there are still error messages after the second attempt, call FreeFlight. 26. Updating the 2101 I/O Approach Plus to operating system version –...
Page 23 The software MUST be loaded in the correct order, as described in the instructions immediately following this box. The loading options on the 2101 I/O Plus display will not be presented in that order. Therefore, take care to follow the loading directions in this Service Bulletin EXACTLY IN SEQUENCE AS WRITTEN.
Page 24 Verify that the Software Version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. Press NAV. The following message will appear. AIO: 1.21 EEF4E834 PUSH NAV TO CONTINUE Verify that the Software Version and CRC on the top line of the display match the above text.
Page 25 -0241. DO NOT REMOVE THE CARD!) IOP ROM UPDATED OK PWR OFF, REMOVE CARD 17. Turn OFF power to the 2101 I/O Plus. Wait 30 seconds. Turn ON power to the unit. 18. Verify that the following message is displayed: PERFORMING BUILT IN TEST Then the unit will reset.
Page 26 23. Verify that the Software Version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. 24. Press NAV. 25. Verify that the following messages are displayed:...
Page 27 CLEAR BATTERY BACKED MEMORY SUCCESSFUL The unit will reset. Then the following message will be displayed: IOP ROM UPDATED OK PWR OFF, REMOVE CARD 31. Turn the unit OFF. Remove the flash card from the memory card slot and insert a 4 MB database card.
Page 28 IFR NOT ALLOWED If any of the above messages appear, perform the software loading again. If there are still error messages after the second attempt, call FreeFlight. Identification When the software has been successfully loaded with no errors reported, the flash...
Page 29 2101 I/O Approach Plus GPS Navigation Systems, Part Numbers 81440-02-XXXX, 81440- 03-XXXX, 81440-12-XXXX, 81440-32-XXXX, 81440-33-XXXX, and 81440-42-XXXX. Release of operating system –241M. SUMMARY: FreeFlight Systems has released software system –241M for the 2101 I/O Plus. PLANNING INFORMATION Effectivity This Service Bulletin applies to the 2101 I/O Approach Plus GPS Navigators, Part...
Page 30 MATERIAL INFORMATION Price and Availability Call FreeFlight Systems for price and availability at time of purchase. All operators will be charged a $300 media/handling fee for each PCMCIA card shipped. Operators who return a serviceable card within 90 days will receive credit.
Page 31 (15) working days after receipt of the unit, depending upon parts availability. Level II Service Centers wishing to incorporate Service Bulletin 81440-XX-00-23 should issue a purchase order to FreeFlight for the number of Service Bulletin kits required. Parts List...
Page 32 Database Card Insert the flash card into the memory card slot on the front of the unit. Turn power ON to the 2101 I/O Plus. The unit will begin its startup procedure. Verify that the following message is displayed: FLASH CARD DETECTED...
Page 33 PUSH NAV TO CONTINUE Verify that the software version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. Press NAV. The following message will appear. GPS: 5.05B...
Page 34 After the image verification is complete, the unit will reset. Then it will display this message: PERFORMING BUILT IN TEST CLEAR BATTERY BACKED MEMORY SUCCESSFUL FreeFlight 2101 I/O SAR SYSTEM CODE: 241M c2008 It is followed by: IOP ROM UPDATED OK PWR OFF, REMOVE CARD 17.
Page 35 IFR NOT ALLOWED 25. If any of the above messages appear, perform the software loading again. If there are still error messages after the second attempt, call FreeFlight. 26. Updating the 2101 I/O Approach Plus to operating system version –...
Page 36 The software MUST be loaded in the correct order, as described in the instructions immediately following this box. The loading options on the 2101 I/O Plus display will not be presented in that order. Therefore, take care to follow the loading directions in this Service Bulletin EXACTLY IN SEQUENCE AS WRITTEN.
Page 37 Verify that the Software Version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. Press NAV. The following message will appear. AIO: 1.21 EEF4E834 PUSH NAV TO CONTINUE Verify that the Software Version and CRC on the top line of the display match the above text.
Page 38 -0241. DO NOT REMOVE THE CARD!) IOP ROM UPDATED OK PWR OFF, REMOVE CARD 17. Turn OFF power to the 2101 I/O Plus. Wait 30 seconds. Turn ON power to the unit. 18. Verify that the following message is displayed: PERFORMING BUILT IN TEST Then the unit will reset.
Page 39 VERIFYING GPS IMAGE VERIFYING AIO IMAGE After successful image verification, the following message will appear: FLASHCARD IOP, AIO AND GPS IMAGES OK A message quickly flashes by and then the following appears: UPDATE GPS CARD NOW? NAV = YES AUX = NO 26.
Page 40 IFR NOT ALLOWED If any of the above messages appear, perform the software loading again. If there are still error messages after the second attempt, call FreeFlight. Identification When the software has been successfully loaded with no errors reported, the flash...
Page 41 Perform System Reset NAVIGATOR RESET Upon completion of this procedure, the unit will be in "cold start" mode. Please allow up to 15 minutes for GPS acquisition. Memory Reset – 1. With UUT turned OFF, simultaneously press and hold the following keys: NAV, NRST and –D>...
Page 42 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 43 2101 I/O Approach Plus GPS Navigation Systems, Part Numbers 81440-02-XXXX, 81440- 03-XXXX, 81440-12-XXXX, 81440-32-XXXX, 81440-33-XXXX, and 81440-42-XXXX. Release of operating system –241N. SUMMARY: FreeFlight Systems has released software system –241N for the 2101 I/O Plus. PLANNING INFORMATION Effectivity This Service Bulletin applies to the 2101 I/O Approach Plus GPS Navigators, Part...
Page 44 Improved presentation of DME arcs on serial and ARINC outputs and corrected a problem with joining DME arcs Fixed representation of PTURN waypoints in serial and ARINC outputs Fixed problem with system restarts when a DME arc is preceded by the DME arc center waypoint Changed representation of direct-to waypoint to avoid compatibility issues with some MFDs...
Page 45 (15) working days after receipt of the unit, depending upon parts availability. Level II Service Centers wishing to incorporate Service Bulletin 81440-XX-0025should issue a purchase order to FreeFlight for the number of Service Bulletin kits required. Parts List Service Bulletin Kit 81440-XX-00-25 contains:...
Page 46 Ordering Information Operators of the 2101 I/O Approach Plus wishing to upgrade their system may send the unit(s) to an approved Level II Service Center or the FreeFlight Factory Service Center. To upgrade the operating system at a Level II Service Center, send a purchase order...
Page 47 Database Card Insert the flash card into the memory card slot on the front of the unit. Turn power ON to the 2101 I/O Plus. The unit will begin its startup procedure. Verify that the following message is displayed: FLASH CARD DETECTED...
Page 48 Verify that the Software Version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. 10. Press NAV. 11. Verify that the following messages are displayed. A pattern will scroll across the bottom line of the display to indicate that the image verification process is taking place.
Page 49 CLEAR BATTERY BACKED MEMORY SUCCESSFUL FreeFlight 2101 I/O SAR SYSTEM CODE: 241N c2010 It is followed by: IOP ROM UPDATED OK PWR OFF, REMOVE CARD 17. Turn the unit OFF. Remove the flash card from the memory card slot and insert a 4 MB database card.
Page 50 IFR NOT ALLOWED 25. If any of the above messages appear, perform the software loading again. If there are still error messages after the second attempt, call FreeFlight. 26. Updating the 2101 I/O Approach Plus to operating system version –...
Page 51 The software MUST be loaded in the correct order, as described in the instructions immediately following this box. The loading options on the 2101 I/O Plus display will not be presented in that order. Therefore, take care to follow the loading directions in this Service Bulletin EXACTLY IN SEQUENCE AS WRITTEN.
Page 52 Verify that the Software Version and CRC on the top line of the display match the above text. If not, then terminate the programming procedure immediately and contact FreeFlight. Press NAV. The following message will appear. AIO: 1.22 A46E2325 PUSH NAV TO CONTINUE Verify that the Software Version and CRC on the top line of the display match the above text.
Page 53 -0241. DO NOT REMOVE THE CARD!) IOP ROM UPDATED OK PWR OFF, REMOVE CARD 17. Turn OFF power to the 2101 I/O Plus. Wait 30 seconds. Turn ON power to the unit. 18. Verify that the following message is displayed: PERFORMING BUILT IN TEST Then the unit will reset.
Page 54 VERIFYING GPS IMAGE VERIFYING AIO IMAGE After successful image verification, the following message will appear: FLASHCARD IOP, AIO AND GPS IMAGES OK A message quickly flashes by and then the following appears: UPDATE GPS CARD NOW? NAV = YES AUX = NO 26.
Page 55 IFR NOT ALLOWED If any of the above messages appear, perform the software loading again. If there are still error messages after the second attempt, call FreeFlight. Identification When the software has been successfully loaded with no errors reported, the flash...
Page 56 Perform System Reset NAVIGATOR RESET Upon completion of this procedure, the unit will be in "cold start" mode. Please allow up to 15 minutes for GPS acquisition. Memory Reset – 1. With UUT turned OFF, simultaneously press and hold the following keys: NAV, NRST and –D>...
Page 57 2101 I/O Plus Display Components Maintenance Manual LIST OF EFFECTIVE PAGES Insert latest change pages and destroy superseded pages. Dates of Original and Change pages are: Original ....1 November 1997 Rev. A ..20 January 2004 Rev. B ..15 March 2007 Page Description Page No.
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Page 59: Table Of Contents
2101 I/O Plus Display Components Maintenance Manual TABLE OF CONTENTS INTRODUCTION ............................. INTRO-1 DESCRIPTION AND OPERATION ..........................1 1. Physical Description ............................1 2. System Description ............................2 3. Functional Description ........................... 3 A. RDU Operation ............................3 B. Front Panel Layout and Description ......................5 (1) Power Switch............................
Page 60 2101 I/O Plus Display Components Maintenance Manual 2. Equipment and Materials ......................... 501 3. Procedures ............................... 501 A. Examine ............................501 B. Make Sure ............................501 C. Check Lithium Battery ........................502 REPAIR..................................601 1. Task ................................601 2. Equipment and Materials ......................... 601 A.
Page 61 Figure Intro-1 Hazardous Material Warning ....................INTRO-3 Figure Intro-2 Caution Label ...........................INTRO-3 Figure 1 2101 I/O Plus Receiver Display Unit ....................1 Figure 2 2101 I/O Plus System ........................4 Figure 3 2101 I/O Plus to Aircraft Interface ...................... 5 Figure 4 Front Panel Functionality ........................
Page 62 2101 I/O Plus Display Components Maintenance Manual Table 3 DADS Digital Input ........................... 15 Table 4 AHRS Digital Inputs ......................... 15 Table 5 Radar / Digital Inputs ........................15 Table 6 Fuel Digital Inputs ..........................16 Table 7 GNS Digital Inputs .......................... 16 Table 8 ARINC 429 Output Parameters ..........
Page 63: Introduction
By performance, 16 April, 1997 Table Intro-2: Level of Verification FreeFlight will revise this manual as necessary to provide current data. The sources for data supplied in this manual include engineering drawings and change orders released as of 25 April 1997.
Page 64 2101 I/O Plus Display Components Maintenance Manual Abbreviations Weights and measurements in this manual are in U.S. values. The letter symbols for units of measurement and the abbreviations are the same as shown in ANSI/IEEE Std 260 and ASME Y1.1, except as identified in Table Intro-3.
Page 65: Figure Intro-1 Hazardous Material Warning
Figure Intro-2: Caution Label The 2101 I/O Plus Receiver Display Unit contains parts that are electrostatic sensitive. If you do not obey the necessary controls, a failure or degraded operation of the unit can occur because of static electrical voltages. Use approved industry precautions to keep the risk of damage to a minimum when you touch, remove, or insert static-sensitive devices.
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Page 67: Description And Operation
2101 I/O Plus Display Components Maintenance Manual DESCRIPTION AND OPERATION 1. Physical Description The 2101 I/O Plus Receiver Display Unit (RDU) is a cockpit Dzus-mounted assembly that consists of the following parts: • Top Case • Circuit Card Assemblies (CCA) A1 through A6 • Bottom Case • Display Panel (CCA A7) with either black or gray bezel:...
Page 68: System Description
2101 I/O Plus Display Components Maintenance Manual Dimensions (maximum) Height ........................3.0 in. ( 762 mm) Width ........................5.7 in. (1449 mm) Depth ........................7.68 in. (1950 mm) Weight ......................... 3.25 lb (1.48 kg) Temperature: Navigation Unit ........................ -20 to +70 °C Database Card ........................0 to +55 °C RDU Mounting ...........................Dzus Rail Power Requirements ....................... 28 V dc @ 1.5A Connectors: RDU #1 ..........................FFS 80251 (MS27508E14B35A) RDU #2 ..........................FFS 80253 (MS27508E18B35P) Antenna Cable Assembly.....................
Page 69: Functional Description
2101 I/O Plus Display Components Maintenance Manual The 2101 I/O Plus (Figure 2) line-replaceable units (LRUs) are: • GPS Antenna/Preamplifier Unit • Receiver Display Unit The GPS antenna contains an omnidirectional flat micro-strip antenna with an integral preamplifier. The RDU contains all of the system processing power and uses three different software units: • GPS processor for GPS signal processing and navigation •...
Page 70: Figure 2 2101 I/O Plus System
2101 I/O Plus Display Components Maintenance Manual Figure 2: 2101 I/O Plus System Revision B Use or disclosure of information on this page is subject to the Page 4 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 71: Front Panel Layout And Description
2101 I/O Plus Display Components Maintenance Manual Figure 3: 2101 I/O Plus to Aircraft Interface Some data pages contain fields that are changeable. The selector knobs and the ENT function key are used to enter or change information on a data page. B. Front Panel Layout and Description The RDU front panel features a two line high-intensity alphanumeric Light Emitting Diode (LED) dot-matrix display.
Page 72: Power Switch
2101 I/O Plus Display Components Maintenance Manual The functional description of the RDU can be separated into the following areas: • Power Switch • LED Display • Annunciators • Mode Keys • Function Keys • Selector Knobs Each functional area is discussed below. Figure 4 shows the functionality grouping of the front panel. (1) Power Switch The RDU has one power switch located at the top of the unit. When the power is turned ON, the system performs a series of self-diagnostic tests. When these tests are successfully completed, a “Ready for Navigation” or "Fuel on Board" message appears.
Page 73 2101 I/O Plus Display Components Maintenance Manual NOTE: The RAIM and GPS Internal Annunciator lights have no function in software versions -241A and higher. (4) Mode Keys The front panel contains six mode keys (Figure 4) located in two rows at the bottom of the front panel. The keys are used to select an RDU mode of operation. When a key is pressed, it illuminates to confirm selection of that mode. Pressing a key for 1 to 1½ seconds returns the display to the primary page of the mode. The following is a brief description of each mode key and its function: (a) NAV Mode The Navigation (NAV) mode is the primary RDU mode and is used to access navigation information.
Page 74: Function Keys
2101 I/O Plus Display Components Maintenance Manual • Approaches • • Agencies • NDBs • Intersections • User waypoints Function Keys Three function keys (Figure 4) are located on the front panel. Each function key has a unique set of applications. The following paragraphs provide a brief description of each function key: (a) Direct ( D ) Key The function of the Direct (D ) key is to select a new active waypoint or a specific course inbound or outbound to or from the current active waypoint. The key is also used to activate a flight plan,...
Page 75: Selector Knobs
2101 I/O Plus Display Components Maintenance Manual Direct ( D ) key operations are: (1st Press) - Selects displayed waypoint, procedure, or flight plan for activation (2nd Press) - Activates course steering as selected (Escape) - Select any other key MSG Key The Message (MSG) key is used to view messages on the display that do not automatically pop-up.
Page 76: Rdu Circuit Card Assemblies
2101 I/O Plus Display Components Maintenance Manual • GPS Antenna Failure • Database Failure • Database Out-of-Date C. RDU Circuit Card Assemblies To assist in the troubleshooting process, a block diagram and an explanation of the block diagram for each of the following circuit card assemblies is provided: • Power Supply CCA (A1) • Synchro Power/Filter CCA (A3/A2) • Interface CCA (A4) • GPS Sensor CCA (A5) • Processor Board CCA (A6) • Display Assembly CCA (A7) (1) Power Supply CCA (A1) The power supply CCA (A1) develops ±15 V dc, +5 V dc, and +3 V dc (Figure 5). The output voltages are used to supply Vcc and to bias circuitry on the other RDU CCAs. There are no user replaceable components on this CCA.
Page 77: Figure 5 Power Supply Cca (A1)
2101 I/O Plus Display Components Maintenance Manual Figure 5: Power Supply CCA (A1) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 11 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 78: Figure 6 Synchro Power/Filter Cca (A3/A2) (Preferred)
2101 I/O Plus Display Components Maintenance Manual The Synchro Power/Filter CCA (A3/A2) circuits are used to eliminate electromagnetic and electrostatic interference from the synchro drive signals (Figure 6). The CCA has its own ±21 V dc power supply. This power supply provides isolation of the supply voltages used to operate the operational amplifiers, buffers, and ancillary circuits on this CCA. Isolation of the synchro drive circuitry is necessary to ensure “clean” synchro drive voltages are output to the aircraft systems. Six synchro signals are applied to operational amplifiers where they are processed with their reference signals. These signals are buffered to provide for signal isolation and routed through lowpass pi filters. Electromagnetic and electrostatic interference is filtered out by the lowpass pi filters. The synchro signals are then supplied to the appropriate aircraft sensor. The other RDU signals bypass the operational amplifier and buffer stages. However, they are routed through the low pass pi filters to eliminate interference. There are no user replaceable components on this CCA. Figure 6: Synchro Power/Filter CCA (A3/A2)
Page 79: Table 2 Arinc 429 Input Devices
2101 I/O Plus Display Components Maintenance Manual Additional Annunciator Output The annunciator lights are: • Dead Reckoning (DR) • Approach Enable (APR EN) • Approach Mode (APR MDE) (b) Analog Inputs The following analog inputs are processed by the A4 CCA: • Two analog altimeter input (X, Y, Z) • One analog true air speed input (X, Y, Z) • One analog heading input (X, Y, Z) • TAS and HDG ref inputs • HSI Ref Hi signal • STR Ref Hi signal • REF_COM. (c) Analog Outputs The RDU provides analog outputs from the analog output circuits to the discrete I/O for interface with aircraft systems. SYN 1X, SYN 2X, SYN 3X, SYN 1Y, SYN 2Y and SYN 3Y are analog outputs routed...
Page 80: Figure 7 Interface Cca (A4)
2101 I/O Plus Display Components Maintenance Manual Figure 7: Interface CCA (A4) Revision B Use or disclosure of information on this page is subject to the Page 14 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 81: Table 3 Dads Digital Input
2101 I/O Plus Display Components Maintenance Manual 1 DADS Input The RDU accepts inputs of True Airspeed (TAS), Pressure Altitude, and Barometrically Corrected Altitude, Total Air Temperature (TAT), and Static Air Temperature (SAT). The system accepts these inputs as ARINC 419/575 or 429 data (Table 3). Label (Octal) Parameter Format 203 A ltitude (Press) 419/575 BNR 204 A ltitude (Baro) 419/575 BNR 210 TAS 419/575 BNR 211 Total Air Temperature 419/575 BNR 230 TAS 419/575 BCD Label (Octal) Parameter Format 203 A ltitude (Press)
Page 82: Table 6 Fuel Digital Inputs
2101 I/O Plus Display Components Maintenance Manual Fuel Input The Fuel input port accepts inputs of Total Fuel and Fuel Flow. Label (Octal) Parameter Format 244 Fuel Flow Rate 429 BNR Table 6: Fuel Digital Inputs GNS (Reserved for Honeywell SLS) Label (Octal) Parameter Format 033 TDS Label-SLS Tuning 101 GNS HDOP 102 GNS VDOP 110...
Page 83 2101 I/O Plus Display Components Maintenance Manual Label (Octal) Parameter Format 075 To/From Waypoint 429 BNR 076 Altitude (MSL) 429 BNR 114 DTK 429 BNR 115 Bearing 429 BNR 116 Crosstrack 429 BNR 121 Steering 429 BNR 125 GMT 429 BCD 147 Magnetic Var 429 BNR 174 Glideslope Deviation 429 BNR 233-236 Flight ID 241H or later...
Page 84: Table 9 Arinc 429 Vdl Output Parameters
2101 I/O Plus Display Components Maintenance Manual Label (Octal) Parameter Format NOTE: The following GAMA data is only sent when GAMA is selected. 074 N o. of Waypoints GAMA 261 GPS Discrete Word 1 GAMA 303 Waypoint Rec. Start GAMA 304 WPT ID (1-3) GAMA 305 WPT ID (4-6) GAMA 306 WPT Latitude GAMA 307 WPT Longitude GAMA 326 Latitude Deviation Scale Factor 429 BNR 327...
Page 85: Table 10 Arinc 743 Taws Output Parameters
2101 I/O Plus Display Components Maintenance Manual Port 1 (J2-16 and 23) - Software version 241H or later Port 2 (J2-58 and 57) - Software version 241H or later Label (Octal) Parameter Format 076 Altitude (MSL) 101 HDOP 102 VDOP 103 True Track 110 Latitude 111 Longitude 112 Ground Speed 125 UTC 130 Horizontal Integrity 136 Vertical FOM 147 Mag. Variation 165 Vertical Speed 166 N/S Velocity 174...
Page 86: Table 11 30212 Hardware Configuration
2101 I/O Plus Display Components Maintenance Manual (4) GPS Sensor CCA (A5) The GPS Sensor CCA (Figure 8) contains the following circuits: • Memory • Processor • External Interface • Down Converter • Galileo The basic function of the GPS12 channel is to provide accurate navigation data (position and velocity) to the Processor Board CCA (A6) of a navigation system by acquiring and tracking GPS satellite signals. It shall identify the position within 0.056 nmi and velocity of the vehicle within 5 knots or better. Satellite acquisition and signal tracking are performed through interfaces to the GPS receiver hardware. The GPS signals are processed and sent to navigation routines which produce position and velocity estimates which are sent to the processor board via an 8-bit parallel interface. The GPS12 software shall communicate with the host and a serial interface. The processor hardware (68340) shall communicate via Galileo chips, A-to-D converter (ADC), 8-bit parallel bus (buffer) and DUART. (a) Memory 30212 hardware maintains the battery backed RAM memory while power is turned off. In 84588 hardware, certain data variables are periodically written to flash memory, programmable RF section attenuators and antenna power control. Writing data to flash memory is triggered by any of three events: the receipt of new ephemeris data for any satellite, the receipt of new almanac data for any satellite, or the elapse of 375 seconds since data was last stored in flash. The data recorded in flash includes a version number, a checksum, and...
Page 87: Figure 8 Gps Sensor Cca (A5)
2101 I/O Plus Display Components Maintenance Manual Figure 8: GPS Sensor CCA (A5) Revision B March 15, 2009 Page 21 Use or disclosure of information on this page is subject to the restrictions of the Proprietary Notice on page TITLE-2 of this document.
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Page 89 2101 I/O Plus Display Components Maintenance Manual (d) Down converter After filtering and buffering, the antenna signal goes through two mixers and filters to perform a two-stage down conversion to the final IF. The local oscillator signals for the mixers come from the synthesizer module. In addition to providing the local oscillator signals for the mixers, the synthesizer module also produces other frequencies used by the 12-channel GPS unit processor. The IF module processes the IF signal, amplifying it and limiting it's bandwidth. The resulting signal is fed to the Galileo chips. (e) Galileo The Galileo chip is a custom IC that contains hardware for tracking the GPS signal and extracting carrier and code information, and also provides the millisecond timing interrupt. The GPS12 software controls the operation of the tracking hardware in the Galileo chip. In turn, the Galileo chip provides GPS signal information to the GPS12. (5) Processor Board CCA (A6) The Processor Board CCA (A6) (Figure 9) contains the following circuits: • Memory • Main Processor • UART + ADC • Sensors • Display/Keyboard Interface • System Clocks • External Interface (a) Memory Memory receives read and write enable signals from the main processor for both the lower data string (LDS) and upper data string (UDS).
Page 90 2101 I/O Plus Display Components Maintenance Manual (e) Display Keyboard Interface The display keyboard interface circuits allow interfacing of the display board and data signals. Keyboard inputs to and from the display are buffered. (f) System Clocks System clocks control the timing for the use and display of all RDU data. The master oscillator develops a frequency of 16.0 MHz. This frequency is divided by two to provide 8.0 MHz for the display...
Page 91: Figure 9 Processor Board Cca (A6)
2101 I/O Plus Display Components Maintenance Manual Figure 9: Processor Board CCA (A6) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 25 restrictions of the Proprietary Notice on page TITLE-2 of this document. The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 92: Figure 10 Display Assembly Cca (A7)
2101 I/O Plus Display Components Maintenance Manual Figure 10: Display Assembly CCA (A7) Revision B Use or disclosure of information on this page is subject to the Page 26 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document. The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 93: Testing And Fault Isolation
Task Use the test procedures in this section to test the 2101 I/O Plus Receiver Display Unit. The test procedures include fault detection and isolation (diagnostics) for Level II repair. Isolation is to the CCA or other Level II subassembly.
Page 94: Table 101-A Essential Test Equipment
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 1 of 17 INTRODUCTION This document contains procedures for final testing of Model 2101 I/O Plus RDU Assembly, 81440-XX. TEST EQUIPMENT The following test equipment is required: Description...
Page 95: Table 101-D Required Software
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 2 of 17 The following software is required on the PC. Software Release Date Purpose IOMON21.EXE 08/30/94 Displays Auxiliary Input Data SPECS.DAT 01/16/97 Contains acceptance bounds for analog tests NAVFT.EXE...
Page 96: Figure 101-Aatp Test Equipment Interconnect
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 3 of 17 Figure 101-A: ATP Test Equipment Interconnect Connect the DC Power Supply to the AC line and turn it ON. Verify a voltage of 28 V 2 V.
Page 97 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 4 of 17 Verify smooth operation of each key. 4.1.3 Power Up Turn ON the power supply. On test set, set UUT 28 VDC switch to ON.
Page 98 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 5 of 17 Press AUX repeatedly until "INSTALL SETUP" is briefly displayed. Rotate the small knob until "SERIAL I/O SETUP" is displayed. Rotate the large knob until "SERIAL 1 I/O" is displayed.
Page 99 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 6 of 17 Perform the following steps only if using software versions 241H or above: Turn outer know clockwise until DIGITAL OUTPUT #1 is displayed. Press ENT.
Page 100: Table 101-Fuut Display
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 7 of 17 Result NAV key is ON, all others dim. NAV key is ON, key is blinking, all others dim. WPT key is ON, all others dim.
Page 101 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 8 of 17 NOTE: GPS and RAIM are used only in test mode. Observe the key LEDs. They should light in the following sequence. NAV, WPT, FPL, CALC, AUX, D , MSG, ENT, NRST NOTE: AUX is always ON.
Page 102 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 9 of 17 4.3.1.1 No. 1 CDI TEST Press AUX until "CONFIGURE" is displayed briefly. Rotate the small knob cw one click until "I/O INTERFACE CHECK" is displayed.
Page 103: Table 101-Gaio Test Points
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 10 of 17 Using the DMM, measure the AC voltages at test points VAC1 and VAC2 and record on the Test Data Record Sheet. Press ENT until TEST SYNCHRO #1 is displayed. Rotate a knob right so 030° is displayed.
Page 104: Table 101-I Discrete Field Display
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 11 of 17 Use the oscilloscope to monitor the PPS test point on the CDI test set cable. It should be a digital signal switching between 0 V ± 1 and 4 V ± 1.5. The period should be one pulse per second and the duty cycle should be approximately 1%.
Page 105: Table 101 Final Test Procedure
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 12 of 17 Switch Reference Field HDGREF 1 1 1 0 0 HSIREF 0 0 0 1 0 STRNGREF 0 0 0 0 1 Table 101-J: Reference Field Display In the *LOOPBACK* field of the PC screen, verify all four of the error counts are less than four.
Page 106 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 13 of 17 Set the Port Selector Switch on the CDI test set cable to Port 3DIF (PORT 3/422). On the PC, press the F9 key. Ensure "Doing position fixes" returns and the position data continues to update.
Page 107 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 14 of 17 Rotate the large knob to Serial-2 in. Press ENT. Rotate small knob to display "ENCODER." Press ENT. Rotate large knob to Serial-2 out. Press ENT.
Page 108 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 15 of 17 Rotate the large knob to display "Serial 2-out." Press ENT. Rotate the small knob to select NONE. Press ENT. Rotate the large knob to Serial-1 in.
Page 109 2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 16 of 17 Press AUX repeatedly until "SYSTEM STATUS" is briefly displayed. If necessary, rotate the small knob until Date and Time are displayed. Compare the current time to a clock or watch, and note the difference.
Page 110: Table 101-L Specs.dat File List
2101 I/O Plus Display Components Maintenance Manual Table 101: Final Test Procedure Part 17 of 17 4.7.4 User Waypoint Entry Press WPT repeatedly until the upper display reads “USER." Rotate the small knob to view the waypoint recorded in step 4.1.6.
Page 111: Auxiliary Output Tests
2101 I/O Plus Display Components Maintenance Manual 2101 I/O Plus Final Test Record TNL 2101 I/O Plus P/N: 81440-_____-___________Serial#:_________________________ Work Order #: _______________________ SB Start Date: _________________________ 10 11 12 13 14 15 16 17 18 19 20 21 22...
Page 112: Figure 116 Auxiliary Input Tests
2101 I/O Plus Display Components Maintenance Manual Failed Test Step No. Fault Isolation Procedure Figure No. 4.1.1 Set Up 4.1.2 Key Test 4.1.3 Power Up 4.1.4 Software Configuration 4.1.5 System Configuration 4.1.6 Save Waypoint 4.1.7 Power Interrupt Test 4.2.1 Button Light Tests 4.2.2 Knob Input Tests...
Page 113: Figure 101 Set Up
2101 I/O Plus Display Components Maintenance Manual Figures 101 through 126 refer to software version -241A and above. Tests are found in Table 101, Section 4.0. Figure 101: Set Up Revision B Use or disclosure of information on this page is subject to the...
Page 114: Figure 102 Key Test
2101 I/O Plus Display Components Maintenance Manual Figure 102: Key Test Revision B Use or disclosure of information on this page is subject to the Page 122 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 115: Figure 103 Power Up
2101 I/O Plus Display Components Maintenance Manual TURN ON TEST SET POWER SUPPLY. TURN RDU ON. REMOVE POWER FROM TEST SET. TURNS DISCONNECT J1 AND J2 FROM RDU. CONTINUITY BETWEEN REPLACE ON/OFF RETEST RDU CENTER AND PIN 2 SWITCH OF ON/OFF...
Page 116: Figure 104 Software Configuration
2101 I/O Plus Display Components Maintenance Manual REPROGRAM FAIL SECOND TIME? Figure 104: Software Configuration Revision B Use or disclosure of information on this page is subject to the Page 124 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 117: Figure 105 System Configuration
2101 I/O Plus Display Components Maintenance Manual Figure 105: System Configuration (Sheet 1 of 3) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 125 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 118 2101 I/O Plus Display Components Maintenance Manual Figure 105: System Configuration (Sheet 2 of 3) Revision B Use or disclosure of information on this page is subject to the Page 126 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 119 2101 I/O Plus Display Components Maintenance Manual Figure 105: System Configuration (Sheet 3 of 3) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 127 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 120: Figure 106 Save Waypoint
2101 I/O Plus Display Components Maintenance Manual Figure 106: Save Waypoint Revision B Use or disclosure of information on this page is subject to the Page 128 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 121: Figure 107 Power Interrupt Test
2101 I/O Plus Display Components Maintenance Manual Figure 107: Power Interrupt Test Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 129 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 122: Figure 108 Button Light Tests
2101 I/O Plus Display Components Maintenance Manual Figure 108: Button Light Tests (Sheet 1 of 2) Revision B Use or disclosure of information on this page is subject to the Page 130 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 123 2101 I/O Plus Display Components Maintenance Manual Figure 108: Button Light Tests (Sheet 2 of 2) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 131 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 124: Figure 109 Knob Input Tests
2101 I/O Plus Display Components Maintenance Manual Note: 241C or higher is 8 clicks Figure 109: Knob Input Tests (Sheet 1 of 2) Revision B Use or disclosure of information on this page is subject to the Page 132 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 125 2101 I/O Plus Display Components Maintenance Manual Figure 109: Knob Input Tests (Sheet 2 of 2) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 133 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 126: Figure 110 Display Tests
2101 I/O Plus Display Components Maintenance Manual Figure 110: Display Tests Revision B Use or disclosure of information on this page is subject to the Page 134 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 127: Figure 111 Display Intensity Tests
2101 I/O Plus Display Components Maintenance Manual Figure 111: Display Intensity Tests Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 135 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 128: Figure 112 Audio Output Tests
2101 I/O Plus Display Components Maintenance Manual Figure 112: Audio Output Tests Revision B Use or disclosure of information on this page is subject to the Page 136 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 129: Figure 113 No. 1 Cdi Test
2101 I/O Plus Display Components Maintenance Manual Figure 113: No. 1 CDI Test Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 137 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 130: Figure 114 No. 2 Cdi Test
2101 I/O Plus Display Components Maintenance Manual Figure 114: No. 2 CDI Test Revision B Use or disclosure of information on this page is subject to the Page 138 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 131: Figure 115 External Lamps And Flags Test
2101 I/O Plus Display Components Maintenance Manual Figure 115: External Lamps and Flags Tests Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 139 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 132 2101 I/O Plus Display Components Maintenance Manual Figure 116: Auxiliary Output Tests (Sheet 1 of 3) Revision B Use or disclosure of information on this page is subject to the Page 140 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 133 2101 I/O Plus Display Components Maintenance Manual Figure 116: Auxiliary Output Test (Sheet 2 of 3) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 141 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 134 2101 I/O Plus Display Components Maintenance Manual Figure 116: Auxiliary Output Tests (Sheet 3 of 3) Revision B Use or disclosure of information on this page is subject to the Page 142 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 135: Figure 117 Miscellaneous Output Tests
2101 I/O Plus Display Components Maintenance Manual Figure 117: Miscellaneous Output Tests Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 143 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 136 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 1 of 7) Revision B Use or disclosure of information on this page is subject to the Page 144 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 137 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 2 of 7) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 145 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 138 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 3 of 7) Revision B Use or disclosure of information on this page is subject to the Page 146 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 139 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 4 of 7) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 147 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 140 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 5 of 7) Revision B Use or disclosure of information on this page is subject to the Page 148 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 141 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 6 of 7) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 149 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 142 2101 I/O Plus Display Components Maintenance Manual Figure 118: Auxiliary Input Tests (Sheet 7 of 7) Revision B Use or disclosure of information on this page is subject to the Page 150 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 143: Figure 119 Gps Receiver Tests
2101 I/O Plus Display Components Maintenance Manual VERIFY RDU ON AND POWERED UP SET CD PORT SELECTOR SWITCH TO 3BIP TYPE NAVFT FOLLOWED BY <ENTER> ON THE PC "DOING POSITION WAIT 5 MINUTES FIXES" ON PC SCREEN? RETEST RDU "DOING...
Page 144: Figure 120 Serial Port 2 Tests
2101 I/O Plus Display Components Maintenance Manual Note: If 241A or 241B = Serial Figure 120: Serial Port 2 Tests (Sheet 1 of 4) Revision B Use or disclosure of information on this page is subject to the Page 152 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 145 2101 I/O Plus Display Components Maintenance Manual Figure 120: Serial Port 2 Tests (Sheet 2 of 4) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 153 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 146 2101 I/O Plus Display Components Maintenance Manual Figure 120: Serial Port 2 Tests (Sheet 3 of 4) Revision B Use or disclosure of information on this page is subject to the Page 154 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 147 2101 I/O Plus Display Components Maintenance Manual Figure 120: Serial Port 2 Tests (Sheet 4 of 4) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 155 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 148: Figure 121 Serial Port 1 Tests
2101 I/O Plus Display Components Maintenance Manual ROTATE LARGE KNOB UNTIL PRESS ALTITUDE INPUT IS DISPLAYED SET TO SERIAL-2 Note: If 241A or 241B = Serial Figure 121: Serial Port 1 Tests (Sheet 1 of 3) Revision B Use or disclosure of information on this page is subject to the...
Page 149 2101 I/O Plus Display Components Maintenance Manual Figure 121: Serial Port 1 Tests (Sheet 2 of 3) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 157 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 150 2101 I/O Plus Display Components Maintenance Manual Figure 121: Serial Port 1 Tests (Sheet 3 of 3) Revision B Use or disclosure of information on this page is subject to the Page 158 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 151: Figure 122 Data Card Tests
2101 I/O Plus Display Components Maintenance Manual Figure 122: Data Card Tests Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 159 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 152: Figure 123 Analog Converter Tests
2101 I/O Plus Display Components Maintenance Manual Figure 123: Analog Converter Tests (Sheet 1 of 2) Revision B Use or disclosure of information on this page is subject to the Page 160 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 153 2101 I/O Plus Display Components Maintenance Manual Figure 123: Analog Converter Tests (Sheet 2 of 2) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 161 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 154: Figure 124 Real-Time Clock Tests
2101 I/O Plus Display Components Maintenance Manual Figure 124: Real-Time Clock Tests Revision B Use or disclosure of information on this page is subject to the Page 162 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 155: Figure 125 User Waypoint Entry
2101 I/O Plus Display Components Maintenance Manual Figure 125: User Waypoint Entry Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 163 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 156 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 157: Disassembly
Task Use these procedures to remove parts from the 2101 I/O Plus RDU to do cleaning, checks, and replacement of parts as necessary. Refer to figure and item numbers in the ILLUSTRATED PARTS LIST (IPL) to show you where to find the parts to remove.
Page 158: Circuit Card Assembly Stack Removal
2101 I/O Plus Display Components Maintenance Manual THE DISPLAY ASSEMBLY SHOULD BE REMOVED CAREFULLY TO AVOID PIN DAMAGE TO THE MATING CONNECTORS. (2) Remove display assembly (135) from lower case (145). (3) Remove seven screws (45) securing lower case (145) to circuit board assembly A6 (125).
Page 159: Cleaning
Task To clean the 2101 I/O Plus RDU, remove dust, dirt, and unwanted oil and grease. This prevents corrosion and prepares surfaces so you can apply a finish or paint. Be careful when you clean the equipment so you do not damage it.
Page 160: Clean External Parts
2101 I/O Plus Display Components Maintenance Manual CAUTIONS USE ISOPROPYL ALCOHOL CAREFULLY WHEN YOU CLEAN FLUX FROM SOLDER CONNECTIONS. DO NOT LET THE SOLVENT TOUCH THE CONNECTOR BODY. FREON, ACRYLIC, TOLUIC, OR ETHYLENE TYPE SOLVENTS ARE NOT PERMITTED BECAUSE THEY DAMAGE THERMO-PLASTIC CONNECTORS.
Page 161: Check
2101 I/O Plus Display Components Maintenance Manual CHECK Task Visual checks are to be performed during the testing, maintenance and repair of the 2101 I/O RDU. These visual checks make sure the parts of the RDU are physically intact and show no signs of wear, damage, or possible failure.
Page 162: Check Lithium Battery
2101 I/O Plus Display Components Maintenance Manual • Dirt • Chips • Solder splashes • Other particles and substances you do not want (2) All parts are satisfactorily attached. (3) All hardware is installed and tight. (4) Connector pins are not bent or damaged. (5) Solder connections are correctly attached and the solder is applied correctly. (6) Wires do not touch any sharp edges of the chassis, screw threads, or other surfaces that can damage the insulation.
Page 163: Repair
REPAIR Task Repair of the 2101 I/O Plus RDU is to the subassembly level. This section shows you how to perform authorized repair of subassemblies which were found to be defective during testing. Repair of the 2101 I/O Plus RDU is usually: •...
Page 164: Precautions For Lithium Batteries
2101 I/O Plus Display Components Maintenance Manual Sleeve, AWG 24 wire size - Optional source Crocus cloth, grade 4/0 - Optional source Precautions for Lithium Batteries To keep the batteries reliable, it is important to (1) prevent damage to the battery container and (2) to not do any maintenance procedures that could cause the loss of cell capacity, the cell to overheat and explode, or the electrolyte to leak. How to Prepare for Maintenance The battery is made with a lithium electrode and thionyl chloride (liquid electrolyte). If the container breaks open and moisture or water reaches the lithium, sudden flames can occur. Use graphite powder, not water, to extinquish any flames. Fumes from lithium and thionyl chloride electrolyte are poisonous and caustic. If a failure occurs, do not breathe in the fumes nor touch the battery. (1) Wear gloves for protection from the corrosive electrolyte that can leak from the battery container. (2) Wear full safety goggles for protection from a possible battery explosion.
Page 165: Paint Touch-Up Procedures
2101 I/O Plus Display Components Maintenance Manual (2) Replace Battery (a) For access to CCA A6 (125, IPL Figure 1), perform disassembly of the circuit card assembly stack according to the procedures in DISASSEMBLY. (b) Heatsink and desolder each battery lead. (c) Remove battery (130), Part No. 12047, noting polarity. (d) Dispose of battery properly. (e) Add insulation sleeve to positive side of battery lead. (f) Place battery (130), Part No. 12047 on CCA A6 (125) observing correct polarity. (g) Heatsink and solder each battery lead. (h) Install CCA A6 (125) according to the procedures in ASSEMBLY. (i) Test battery using procedures in TESTING AND FAULT ISOLATION. Paint Touch-up Procedures (1) Sand all areas to be painted with a grade 4/0 crocus cloth. (2) Clean the surfaces to be painted with a clean cloth moistened with isopropyl alcohol. Description Paint IPL Figure/Item No.
Page 166 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 167: Assembly (Including Storage)
2101 I/O Plus Display Components Maintenance Manual ASSEMBLY (Including Storage) 1. Task This section provides instructions to assemble the 2101 I/O RDU. Do only those procedures applicable to the level of disassembly. Refer to figure and item numbers in the ILLUSTRATED PART LIST (IPL) to show you the location of the parts as they are assembled. The applicable figure number in the IPL is given in each primary paragraph and does not change until specified differently. Refer to number 4 for storage instructions.
Page 168: Cca A1
2101 I/O Plus Display Components Maintenance Manual Figure 701: Control Cable Connection A6 (125) connector P701. (b) Secure CCA A3/A2 (75) to standoffs (85) with one screw (65) and four screws (70). (4) CCA A1 (a) Carefully mate CCA A1 (55) connectors J505 and J506 to CCA A6 (125) connectors P505 and P506. (b) Connect lead assembly connecting CCA A3/A2 (75) to mating connector on CCA A1 (55). (c) Connect filter/power cable assembly (60) from CCA A3/A2 (75) to mating connector on CCA A1 (55). See Figure 702 for correct connector positioning. B. Lower Case Installation (1) Position circuit card assembly stack in lower case (145). (2) Attach lower case (145) to side of CCA A1 (55) with two screws (50). (3) Attach lower case (145) to CCA A6 (125) with seven screws (45). (4) Mate Display Assembly A7 (135) connector to CCA A6 (125) connector. (5) Attach Display Assembly (A7) (135) to lower case (145) with four screws (45). C. Upper Case Installation (1) Install cable assembly (95) through rear of upper case. (2) Make sure that gasket is in place on connector.
Page 169: Storage
2101 I/O Plus Display Components Maintenance Manual Figure 702: Filter/Power Cable Connection (3) Install lock washer and nut onto connector, and tighten. (4) Set upper case (40) over lower case (145). (5) Slide forward over connectors A2J1 and A2J2. (6) Attach CCA A3/A2 (75) to back of upper case (40) with eight screws (25). (7) Attach the bottom flange of the upper case (40) to the lower case (145) with two screws (20). (8) Attach sides of the upper case (40) to the lower case (145) with eight screws (20). (9) Attach upper case (40) to the CCA rack with one screw (30) in top of upper case (40). Assembly of the RDU is complete. Test the RDU in accordance with TESTING AND FAULT ISOLATION. Storage A. Task Use these instructions to store or ship the RDU. If you must keep the RDU in storage for long periods, keep it in conditions with a temperature range of -30 to +55 °C (-20 to +131 °F). For extended time in storage, you must protect the RDU from dust, moisture, and other contamination. When you send equipment to FreeFlight for warranty repair, you must use the approved ATA container, or equivalent. Warranty responsibility is contingent upon the use of a specified ATA container. B. Equipment and Materials NOTES: 1. Equivalent alternatives are permitted for the equipment and materials in this list.
Page 170: Procedures
2101 I/O Plus Display Components Maintenance Manual Dunnage - Polyurethane, polyether, fire retardant, with a density of 1.2 to 1.3 pounds per cubic ft. Top: 8 by 8 by 4 inches with 1.5 in. nubbins Bottom: 10 by 10 by 7.5 inches with 1.5 in. nubbins CAUTION THIS EQUIPMENT IS SENSITIVE TO DAMAGE BY ELECTROSTATIC DISCHARGE. USE PROTECTIVE PROCEDURES. C. Procedures CAUTIONS: 1. THIS EQUIPMENT IS ELECTROSTATIC DISCHARGE SENSITIVE. DO NOT PUT IT NEAR STRONG ELECTROSTATIC, ELECTROMAGNETIC, MAGNETIC, OR RADIOACTIVE FIELDS. 2. DO NOT USE CARTON TAPE. REMOVAL OF TAPE DAMAGES THE CONTAINER AND SHORTENS THE USABLE LIFE SPAN OF THE CONTAINER. (1) Put the CCA into a static shielding bag that is sufficient in size to contain the CCA. (2) Fold the mouth of the bag over to enclose the CCA. Do not seal the bag. (3) Place the CCA into the container on top of a layer of foam protection.
Page 171: Special Tools, Fixtures, And Equipment
2101 I/O Plus Display Components Maintenance Manual SPECIAL TOOLS, FIXTURES, AND EQUIPMENT Task This section gives all the tools, fixtures, and equipment specified in the other sections. These tools are necessary to do the maintenance on the 2101 I/O RDU. The materials necessary for maintenance are not included in this section. They are identified under the subheading where they are used. The list of tools, fixtures, and equipment in paragraph 2 includes the source of supply. The applicable supply code (also known as the CAGE code) from the Cataloging Handbook H4/H8, Commercial and Government Entity (CAGE), Sections A and B is shown in parentheses after the source of supply. Use the CAGE code to get the full identification of the supplier.
Page 172 2101 I/O Plus Display Components Maintenance Manual PC, 386 with VGA monitor and 1 comm port Counter PM-6666 or Equiv. DC Power Supply, 28 V ± 1 V @ 3 Ampere Serial cable, test set to PC Cable, RDU to GPS Antenna Cable, DC Power, two-wire, 22 AWG minimum with bare wire or banana plug terminations at both ends. Power Supply, 115 V ac, 400 Hz Revision B Use or disclosure of information on this page is subject to the Page 902 March 15, 2009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 173: Illustrated Parts List
Introduction The Illustrated Parts List gives the parts used to make the 2101 I/O Plus RDU. It also supplies the necessary data to get replacement parts for repair and fault isolation. The list of parts is given in general disassembly sequence. The illustrations show where you can find each part and are an important aid in disassembly and assembly procedures.
Page 174: Supplier Codes
(3) The PART NUMBER column shows the part number given by the primary source of the part, either FreeFlight or a commercial supplier, or the part number of a U.S. standard part. When this column shows the part number of a commercial supplier or a U.S. standard part, the NOMENCLATURE column shows the FreeFlight part number.
Page 175: Abbreviations And Symbols
2101 I/O Plus Display Components Maintenance Manual When the supplier has no code number, the name and address of the supplier are given in the NOMENCLATURE column of the Parts List. Abbreviations and Symbols Abbreviations ASME Y1.1 is used as the standard for abbreviations. The abbreviations that are not included in ASME Y1.1 are...
Page 176: Table 1001 List Of Suppliers
2101 I/O Plus Display Components Maintenance Manual CODE SUPPLIER CODE SUPPLIER 1WAN0 FREEFLIGHT SYSTEMS 3700 IH 35 S. WACO, TX 76706 Table 1001: List of Suppliers Revision B Use or disclosure of information on this page is subject to the...
Page 177: Table 1002 Equipment Designator Index
2101 I/O Plus Display Components Maintenance Manual EQUIPMENT DESIGNATOR INDEX EQUIPMENT FIG. ITEM PART EQUIPMENT FIG. ITEM PART DESIGNATOR NUMBER DESIGNATOR NUMBER 1 55 80932-10 1-55A 80932-00 A3/A2 1 75 81675-00-A 1 90 81874-00-A 1-105 84588-10 1-105A 30212-10 1-125 82875-01-A...
Page 178 2101 I/O Plus Display Components Maintenance Manual NUMERICAL INDEX AIRLINE FIG. PART NUMBER STOCK NO. ITEM 12047 1 130 12584 1 65 12815 1 70 16919 20692 1 95 30212-10 1 105A 80064 1 15 80229 1 145 80232 1 140...
Page 179 2101 I/O Plus Display Components Maintenance Manual Figure 1001: Receiver Display Unit (Sheet 1 of 2) Revision B March 15, 2009 Page 1007 Use or disclosure of information on this page is subject to the restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 180 The document reference is online, please check the correspondence between the online documentation and the printed version.
Page 181: Figure 1001
2101 I/O Plus Display Components Maintenance Manual Figure 1001: Receiver Display Unit (Sheet 2 of 2) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 1009 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 182: Table 1004 Parts
2101 I/O Plus Display Components Maintenance Manual UNIT FIG. PART AIRLINE NOMENCLATURE ITEM NUMBER STOCKNO. 1234567 CODE ASSY USABLE ON CODES CODE A 81440-02 CODE B 81440-03 CODE C 81440-12 CODE D 81440-32 CODE E 81440-33 CODE F 81440-42 1 -1...
Page 183 2101 I/O Plus Display Components Maintenance Manual UNIT FIG. PART AIRLINE NOMENCLATURE ITEM NUMBER STOCKNO. 1234567 CODE ASSY 12584 .SCREW PL PH 4-40X0.31 12815 .SCREW PL PH 4-40X0.25 1 75 81675-00-A .CIRCUIT CARD ASSEMBLY- SYNCHRO POWER/FILTER (ESDS) (A3/A2) 80235-00 .CABLE, CONTROL 81338 .STANDOFF, M-F 3-16 HEX...
Page 184 2101 I/O Plus Display Components Maintenance Manual UNIT FIG. PART AIRLINE NOMENCLATURE ITEM NUMBER STOCKNO. 1234567 CODE ASSY 135D 83549-00 .DISPLAY ASSEMBLY BLK NVG C, F (A7) 135E 84720-16 .DISPLAY ASSEMBLY BLK NVG C, F (A7) (PREFERRED PART) 135F 84720-12 .DISPLAY ASSEMBLY GRY...
Page 185: Figure 1002
2101 I/O Plus Display Components Maintenance Manual Figure 1002: Display Assembly - P/N 83480 and 82550 only (Non-NVG) Revision B Use or disclosure of information on this page is subject to the March 15, 2009 Page 1013 restrictions of the Proprietary Notice on page TITLE-2 of this document.
Page 186: Table 1005
2101 I/O Plus Display Components Maintenance Manual For use on 83480 and 82550 faceplates ONLY UNIT FIG. PART AIRLINE NOMENCLATURE ITEM NUMBER STOCKNO. 1234567 CODE ASSY 2 10 83480-SA02 .BEZEL ADDY BLK I/O PLUS 83480-SA05 .BEZEL ASSY GRY I/O PLUS...

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