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Racal Instruments AN/TRC-207 Operation And Maintenance Instructions

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TO 31R2-2TRC207-1
OPERATION AND MAINTENANCE INSTRUCTIONS
WITH ILLUSTRATED PARTS BREAKDOWN
ORGANIZATIONAL LEVEL
RADIO SET
AN/TRC-207
(BI-DIRECTIONAL REPEATER)
RACAL COMMUNICATIONS, INC.
5 RESEARCH PLACE
ROCKVILLE, MD 20850
CONTRACT NO: F19628-91-D-0012
DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government agencies only for administrative
or operational use 15 August, 1996. Other requests for this document shall be referred to Sacramento ALC/TILBE,
3200 Peacekeeper Way, Suite 1, McClellan AFB, CA 95652-1026.
WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title
22, U.S.C., Sec 2751 et seq.) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et
seq.). Violations of these export laws are subject to severe criminal penalties.
HANDLING AND DESTRUCTION NOTICE - Handle in compliance with distribution statement and destroy by any
method that will prevent disclosure of contents or reconstruction of the document.
PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE
15 JULY 1997

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  • Page 1 TO 31R2-2TRC207-1 OPERATION AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN ORGANIZATIONAL LEVEL RADIO SET AN/TRC-207 (BI-DIRECTIONAL REPEATER) RACAL COMMUNICATIONS, INC. 5 RESEARCH PLACE ROCKVILLE, MD 20850 CONTRACT NO: F19628-91-D-0012 DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government agencies only for administrative or operational use 15 August, 1996.
  • Page 2 TO 31R2-2TRC207-1 LIST OF EFFECTIVE PAGES INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES. NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margin of the page. Changes to illustrations are indicated by a vertical line adjacent to the illustration identification number.

  • Page 3: Table Of Contents

    TO 31R2-2TRC207-1 TABLE OF CONTENTS Chapter Page LIST OF ILLUSTRATIONS............................LIST OF TABLES................................SAFETY SUMMARY..............................FOREWORD................................. CHAPTER 1 GENERAL INFORMATION......................1-3 DESCRIPTION AND PURPOSE......................... 1-3 1-1.1 Equipment Function and Purpose ......................1-3 1-1.2 Equipment Description ........................1-3 LEADING PARTICULARS ......................... 1-5 CAPABILITIES AND LIMITATIONS ......................
  • Page 4 TO 31R2-2TRC207-1 CONTROLS AND INDICATORS........................4-1 4-2.1 Indicators, Controls, and Switches.......................4-1 4-2.2 Power Supply Switches and Connectors....................4-1 4-2.3 Connectors............................4-1 Diplexer Control..............................4-1 II. OPERATING INSTRUCTIONS ......................4-7 ECTION OPERATING MODES AND FREQUENCY RECOMMENDATIONS ............4-7 4-3.1 Operating Modes ..........................4-7 4-3.2 Frequency Recommendations.......................4-7 INITIAL POWER-UP AND DIPLEXER TUNING PROCEDURES............4-11 RECEIVING AND RETRANSMITTING MESSAGES................4-12 COVERT OPERATIONS..........................4-13...
  • Page 5 TO 31R2-2TRC207-1 CHAPTER 7 ILLUSTRATED PARTS BREAKDOWN..................7-1 I. INTRODUCTION ............................ 7-1 ECTION GENERAL ..............................7-1 MAINTENANCE PARTS LIST ........................7-1 NUMERICAL INDEX..........................7-2 REFERENCE DESIGNATION INDEX....................... 7-3 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES............. 7-3 CAGE CODE SUMMARY........................... 7-4 II. MAINTENANCE PARTS LIST ......................7-8 ECTION CHAPTER 8 CIRCUIT DIAGRAMS........................8-1 SCOPE ................................

  • Page 6: List Of Illustrations

    Figure 5-3. 15 Watt Power Amplifier Assembly (A1A6), Functional Block Diagram..........5-6 Figure 6-1. Detail of diplexer shock mount assembly ....................6-11 Figure 7-1. Radio Set AN/TRC-207 (Sheet 1 of 2)....................7-8 Figure 7-2. Bi-directional Repeater Assembly (4101027-501) (Sheet 1 of 3) ............7-13 Figure 7-3.
  • Page 7 Table 6-5. Organizational Maintenance Guide - Operator..................6-5 Table 6-6. Organizational Maintenance Guide - Repair Specialist................6-8 Table 6-7. Cross-Reference to Removal/Replacement Procedures................6-9 Table 7-1. Radio Set AN/TRC-207 ..........................7-10 Table 7-2. Bi-directional Repeater Assembly (4101027-501) ..................7-16 Table 7-3. Power AMP Assembly, 15W (SS-4100853-501) ..................7-20...

  • Page 8: Safety Summary

    TO 31R2-2TRC207-1 SAFETY SUMMARY The following are general safety precautions that are not related to any specific procedure, and do not appear elsewhere in this manual. These Safety Summaries are recommended precautions that all personnel must understand and apply during any given phase of operation and maintenance. Each chapter has other specific warnings and cautions. WARNING KEEP AWAY FROM LIVE CIRCUITS Personnel must at all times observe all safety regulations.
  • Page 9 TO 31R2-2TRC207-1 WARNING VOLTAGES WITHIN THIS EQUIPMENT ARE HIGH ENOUGH TO ENDANGER LIFE. Covers are not to be removed except by persons qualified and authorized to do so and these persons should always take extreme care once the covers have been removed. Page WARNING - Installation of the bi-directional repeater requires a minimum of two people.
  • Page 10 TO 31R2-2TRC207-1 This page left blank intentionally. viii...

  • Page 11: Foreword

    TO 31R2-2TRC207-1 FOREWORD This manual meets the technical content requirements of specification MIL-M-38798B, paragraph 3.3 (1 December 1975) and MIL-M-38807A (1 June 1982) and format requirements of specification MIL-M-38784B (16 April 1983) for the bi- directional repeater. Chapter 1 - General Information. This chapter provides general information for the bi-directional repeater including equipment description and purpose, leading particulars, capabilities and limitations, equipment supplied, equipment required but not supplied, optional equipment, special tools and test equipment, and related technical manuals.
  • Page 12 Diplexer Assembly, 403-470 MHz (A3) Rod Assembly, Ground Cable, Coaxial, Antenna (W10) Cable Assembly, 240 VAC, Power (W9) Cable Assembly, 120 VAC, Power (W9) Cable Assembly, 10-32 VDC, Power (W9) Case, Transit, Diplexer Cover, Frame Figure 1-1. Radio Set AN/TRC-207 (Sheet 1 of 3)
  • Page 13 TO 31R2-2TRC207-1 Figure 1-1. Radio Set AN/TRC-207 (Sheet 2 of 3)
  • Page 14 TO 31R2-2TRC207-1 Figure 1-1. Radio Set AN/TRC-207 (Sheet 3 of 3)

  • Page 15: Chapter 1 General Information

    TO 31R2-2TRC207-1 CHAPTER 1 GENERAL INFORMATION DESCRIPTION AND PURPOSE. 1-1.1 Equipment Function and Purpose Radio Set AN/TRC-6728 (hereinafter referred to as the bi-directional repeater or BDR) is a communications unit capable of operating in the 30-88, 136-174, or 403-470 Megahertz (MHz) frequency bands. It is used to extend the communications range of fixed, mobile, or portable receiver-transmitters.

  • Page 16: Figure 1-3. Bdr Diplexer

    TO 31R2-2TRC207-1 Figure 1-1Figure 1-2. Receiver-Transmitter RT-1695/TRC-199 1-1.2.4 Diplexer. (See Figure 1-3.) The BDR diplexer provides a method of using a receiver and a transmitter on a common antenna. The diplexer has three coaxial connector ports - one port connects to the antenna via the power supply and the other two connect to the Radio A and Radio B ports on the BDR.

  • Page 17: Leading Particulars

    TO 31R2-2TRC207-1 1-1.2.5 Power Supply Assembly. The power supply assembly provides power for the operation of the BDR. The power supply will operate from any direct current (DC) voltage between 10 and 32 volts and from 120/240 or 220 volts alternating current (VAC). The operation of the power supply is controlled by the AC/OFF/DC and internal/external (INT/EXT) DC switches on the power supply.

  • Page 18: Capabilities And Limitations

    TO 31R2-2TRC207-1 CAPABILITIES AND LIMITATIONS Capabilities and limitations of the BDR are given in Table 1-3. Table 1-3. Capabilities and Limitations Characteristic Parameter Frequency Range (RCV and XMT) 30-88 MHz 136-174 MHz 403-470 MHz Transmitter Output 2 and 10 watts selectable Security BDR is COMSEC transparent (contains no COMSEC equipment).

  • Page 19: Equipment Supplied

    TO 31R2-2TRC207-1 EQUIPMENT SUPPLIED Equipment supplied with Radio Set AN/TRC-207 is listed in Table 1-4. Table 1-4. Equipment Supplied Official Nomenclature Part Number Quantity BDR Assembly 4101027-501 Power Supply Assembly 4101028-501 $ Power Supply Enclosure $ Battery Enclosure Diplexer Assembly, 30-88 MHz...

  • Page 20: Equipment Required But Not Supplied

    31R2-4-1085-1 Operation and Maintenance Instructions with Illustrated Parts Breakdown (Organizational Level) for Adapter Group OF-228/U 31R2-2TRC207-1 Operation and Maintenance Instructions with Illustrated Parts Breakdown (Organizational Level) for Radio Set AN/TRC-207 31R2-2PRC-139-06 Work Unit Code Manual 35C3-2-113-2 NiCad Battery Reconditioner, MRC-590...

  • Page 21: Chapter 2 Installation

    TO 31R2-2TRC207-1 CHAPTER 2 INSTALLATION INTRODUCTION. This section is divided into two sections. Section I. Installation Logistics provides information for site preparation, unloading, unpacking, and inspections, housing, receiving data, material handling, cabling, and buildings and other structures. Section II. Installation Procedures lists tools and equipment required for field installation and describes the installation sequence.

  • Page 22: Figure 2-1. Packaging Diagram For The Bdr

    TO 31R2-2TRC207-1 Legend for Figure 2-1 Operating instructions Barrier bag Polystyrene top Polystyrene bottom BDR assembly Fiberboard box Desiccant bag Packing slip Figure 2-1. Packaging Diagram for the BDR...

  • Page 23: Housing

    TO 31R2-2TRC207-1 Store all packing materials (except the desiccant bag) in shipping container and store shipping container for re-use. New desiccant material must be used when repacking. Inspect top and bottom, both sides, and front and rear panels of equipment for dents, scratches or any visually identifiable damage.

  • Page 24: Cables

    TO 31R2-2TRC207-1 CABLES. Table 2-2 lists all BDR interconnecting cables. Table 2-2. BDR Interconnecting Cables Cable Cable Part No. Description Designation 4500117-501 Cable Assembly, BDR Power Connects power supply DC output to bi- directional repeater SS-3500292-504 Cable Assembly, Coaxial, RF Connects diplexer receiver (RX) output to bi-directional repeater assembly SS-3500292-505...

  • Page 25: Section Ii. Installation Procedures

    TO 31R2-2TRC207-1 Section II. INSTALLATION PROCEDURES SPECIAL TOOLS AND EQUIPMENT REQUIRED FOR FIELD INSTALLATION. No special tools or equipment are needed for installation and initial setup of the BDR. 2-10 INSTALLATION SEQUENCE (See FO-1.) Perform the following procedure to install the BDR. Cables required for installation are listed in Table 2-2. FO-1 illustrates the required cable connections.

  • Page 26: Figure 2-3. Antenna Mast/Antenna Installation (Sheet 2 Of 6)

    TO 31R2-2TRC207-1 Remove both mast sections from the transit bag (3). Note that the socketed end is the lower end of each section. Place the tubes in line along the ground. Assemble the two tube sections together. Remove the base plate (4), two ground spikes (5), and hammer from the transit bag. Place the base plate at the mast base, arrowhead style, so that the socketed lower end of the mast will engage in the heel.

  • Page 27: Figure 2-5. Antenna Mast/Antenna Installation (Sheet 4 Of 6)

    TO 31R2-2TRC207-1 Figure 2-5. Antenna Mast/Antenna Installation (Sheet 4 of 6) Using the same guy rope as a radius guide, walk across to the approximate location of the second ground anchor. Establish the required 120E from the first ground anchor by using the triangular shape of the base plate as a reference.

  • Page 28: Figure 2-7. Antenna Mast/Antenna Installation (Sheet 6 Of 6)

    TO 31R2-2TRC207-1 Ensure foot of mast is securely located in the base plate heel. While person A pushes up mast head Iwo Jima style, person B pulls on guy ropes to raise mast to vertical. Person A should progressively walk towards bottom of mast as it is raised and should hold mast steady as it reaches the vertical.

  • Page 29: 2-10.2 Lithium Battery Installation

    TO 31R2-2TRC207-1 2-10.2 Lithium Battery Installation. (Optional) (This procedure is also applicable to the Type BB-590/U NiCd batteries.) The battery enclosure has connectors for four type BA-5590/U Lithium batteries. The connectors are mounted in the bottom of the enclosure. To install the batteries, first turn the BDR off using the switch on the top of the power supply enclosure.

  • Page 31: Chapter 3 Preparation For Use And Reshipment

    TO 31R2-2TRC207-1 CHAPTER 3 PREPARATION FOR USE AND RESHIPMENT INTRODUCTION. This chapter is divided into two sections. Section I. Preparation For Use provides post-installation operational checks that must be performed prior to operating the BDR. Section II. Preparation For Reshipment contains procedures for reshipment of the unit.

  • Page 32: 3-3.2 Alignment And Adjustment

    TO 31R2-2TRC207-1 Insert the receiver-transmitter (SS-4100807-512) for the (primary) transmit frequency into the right sleeve (marked "B")of the bi-directional repeater, with the side connector facing up (refer to Figure 1- 1). Turn the cam above the receiver-transmitter clockwise until it locks (1/4 turn). Similarly, insert the receiver-transmitter for the (primary) receive frequency into the left sleeve (marked "A") of the bi-directional repeater and lock it into place.

  • Page 33: Packing

    TO 31R2-2TRC207-1 PACKING. Pack the BDR in the recommended packages illustrated in Figure 2-1. Use original packing materials if available. HANDLING AND STORAGE. Place electronic assemblies in individual containers. This will prevent damage during handling and storage. If a common container is used, use suitable barrier material between electronic assemblies.
  • Page 34 TO 31R2-2TRC207-1 CAUTION Forcing any tilted or cocked electronic assembly into position may result in bent or broken pins. Be very careful when removing or inserting an assembly into the equipment. If it is a plug-in CCA, be sure the guide pins are properly aligned before pressing the assembly in place.

  • Page 35: Chapter 4 Operation

    TO 31R2-2TRC207-1 CHAPTER 4 OPERATION Section I. CONTROLS AND INDICATORS INTRODUCTION This section describes and illustrates indicators, controls, switches, and connectors of the bi-directional repeater. CONTROLS AND INDICATORS. The following paragraphs describe and illustrate all operational controls and indicators of the bi-directional repeater. 4-2.1 Indicators, Controls, and Switches.

  • Page 36: Table 4-1. Description Of Indicators, Controls And Switches

    TO 31R2-2TRC207-1 Table 4-1. Description of Indicators, Controls and Switches Fig & Index Number Control/Switch Function STATUS: 4-1-1 DISPLAY Switch (two- Controls whether the front panel indicators are operational position rotary switch) (ON position) or not operational (OFF position) (The DISPLAY switch should be kept in OFF position to conserve battery life following initial power-up and function check.)

  • Page 37: Figure 4-2. Location Of Power Supply Switches (Power Supply Top View)

    TO 31R2-2TRC207-1 Figure 4-2. Location of Power Supply Switches (Power Supply Top View) Table 4-2. Description of Power Supply Switches Fig & Index Number Switch Function 4-2-1 DC SEL (INT/EXT) Select Allows selecting either the internal battery power source or switch (two-position toggle an external DC source when the AC/DC POWER switch is switch)

  • Page 38: Figure 4-3. Location Of Power Supply Connectors (Power Supply Side View)

    TO 31R2-2TRC207-1 Figure 4-3. Location of Power Supply Connectors (Power Supply Side View) NOTE Both the DC and AC Circuit Breakers (4-3-1 and 4-3-2) MUST be switched ON for AC operation Table 4-3. Description of Power Supply Connectors Fig & Index Number Connectors Function 4-3-1...

  • Page 39: Figure 4-4. Location Of Bi-Directional Repeater Unit Connectors

    TO 31R2-2TRC207-1 Figure 4-4. Location of Bi-Directional Repeater Unit Connectors Table 4-4. Description of Repeater Unit Connectors Fig & Index Number Connectors Function 4-4-1 Radio A/RX (Receive) Input from diplexer receive connector to repeater. Connector J3 4-4-2 POWER Connector J1 Connects repeater to repeater power supply unit.

  • Page 40: Figure 4-5. Location Of Bi-Directional Repeater Diplexer Controls

    TO 31R2-2TRC207-1 Figure 4-5. Location of Bi-Directional Repeater Diplexer Controls Table 4-5. Description of Diplexer Controls Fig & Index Number Control/Switch Function 4-5-1 Tuning Meter Measures relative strength of transmit or receive signals during diplexer tuning. 4-5-2 SENS Control The SENS control is only active when the TUNE switch is held depressed.

  • Page 41: Section Ii. Operating Instructions

    TO 31R2-2TRC207-1 Section II. OPERATING INSTRUCTIONS NOTE Be aware that while performing the initial power-up and diplexer tuning procedures, the bi- directional repeater will radiate RF energy that can cause frequency interference. Do not perform this procedure before the frequency use authorization is obtained and in effect. OPERATING MODES AND FREQUENCY RECOMMENDATIONS This paragraph describes the different modes of operation available with the BDR and provides recommendations for frequency selection to obtain optimum results in each mode.

  • Page 42: Table 4-6. Tr Simplex Mode Recommended Frequencies

    TO 31R2-2TRC207-1 4-3.2.1 Tactical Repeater Mode. Table 4-6. TR Simplex Mode Recommended Frequencies The Mode Select switch should be set to the bi-directional RETRANS position. MODE EQUIPMENT TRANSMIT FREQUENCY RECEIVE FREQUENCY Simplex Base Station Simplex BDR, Radio A Simplex BDR, Radio B Simplex Table 4-7.

  • Page 43: Table 4-9. Tandemed Bdr Recommended Frequencies

    TO 31R2-2TRC207-1 4-3.2.3 Tandemed Bi-Directional Repeater. NOTE HHRs can be programmed with two or more channels to permit the user to access another repeater when one is blocked from view. Table 4-9. Tandemed BDR Recommended Frequencies The Mode Select switch should be set to the bi-directional RETRANS position. EQUIPMENT TRANSMIT FREQUENCY RECEIVE FREQUENCY...

  • Page 44: Figure 4-6. Standard Bdr Cabling Set-Up

    TO 31R2-2TRC207-1 Figure 4-6. Standard BDR Cabling Set-up Figure 4-7. BDR Cross-Banding Cabling Set-up 4-10...

  • Page 45: Initial Power-Up And Diplexer Tuning Procedures

    TO 31R2-2TRC207-1 NOTE The transmit power for RADIO A will always be at peak power regardless of the front panel POWER setting because the routing for RADIO A does not pass through the Power Supply unit, which senses the transmit power and provides gain control back to the power amplifier. Thus, the POWER setting on the front panel only controls the transmit power of RADIO B.

  • Page 46: Receiving And Retransmitting Messages

    TO 31R2-2TRC207-1 Set the SENS control fully clockwise. Place the bi-directional repeater MODE SELECT switch (6, Figure 4-1) in the TUNE B position. Adjust the diplexer XMT tuning dial (4, Figure 4-5) with the red TUNE button (5) depressed until a peak meter indication is noticed.

  • Page 47: Covert Operations

    TO 31R2-2TRC207-1 COVERT OPERATIONS By placing the DISPLAY switch (1, Figure 4-1) in the OFF position, all LEDs on the front panel of the bi-directional repeater are disabled to allow light discipline in blackout conditions. The frame cover is used to further conceal the BDR. Turning off the LEDs also helps to conserve battery power. RECEIVER-TRANSMITTERS For operating procedures for the receiver-transmitters, refer to TO 31R2-2PRC139-1.

  • Page 48: Nuclear, Biological, And Chemical (Nbc) Contamination

    TO 31R2-2TRC207-1 4-11 NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) CONTAMINATION The Scope Shield equipment has a Chemical Agent Resistant Coating (CARC) finish that reduces the susceptibility to NBC contamination. However, in the event the equipment does become contaminated, great care must be exercised in performing decontamination before the equipment can be returned to use.

  • Page 49: Chapter 5 Theory Of Operation

    TO 31R2-2TRC207-1 CHAPTER 5 THEORY OF OPERATION Section I. FUNCTIONAL SYSTEM(S) OPERATION GENERAL This section describes the theory of operation of the bi-directional repeater. From both technical and operational standpoints, the bi-directional repeater is designed to be a component of a communications system. It must function in conjunction with other system components (receiver-transmitters, base stations, and vehicle adapters) to perform communication functions.

  • Page 50: 5-2.7 Rf Matrix Cca (A1A7)

    TO 31R2-2TRC207-1 The amplifier can function over the entire frequency range of 30-470 MHz, with transceiver operation only in the 30-88, 136-174, and 403-470 MHz frequency bands. Figure 5-1. Bi-directional Repeater System, Functional Block Diagram 5-2.7 RF Matrix CCA (A1A7) The RF Matrix CCA (A1A7) provides the mechanism by which the BDR can either receive or transmit through either one of the installed receiver-transmitters.

  • Page 51: 5-2.9 Antenna System

    TO 31R2-2TRC207-1 5-2.9 Antenna System The antenna for the bi-directional repeater provides simultaneous transmit and receive capability. The antenna provides transmit and receive frequency coverage over one of each of the bands of operation. Three antennas cover all of the frequency bands of operation: 30-88 MHz, 136-174 MHz, and 403-470 MHz.

  • Page 52: Watt Power Amplifier Assembly (A1A6)

    TO 31R2-2TRC207-1 Data path - The data path is made up of two slicer circuits (one for each radio) and a Field Programmable Gate Array (FPGA). The purpose of the slicer circuits is to interpret the digital data contained in the analog radio frequency (RF) signals by monitoring the positive and negative signal peaks.

  • Page 53: Figure 5-2. Repeater Control/Audio Cca (A1A2), Functional Block Diagram

    TO 31R2-2TRC207-1 Figure 5-2. Repeater Control/Audio CCA (A1A2), Functional Block Diagram...

  • Page 54: Figure 5-3. 15 Watt Power Amplifier Assembly (A1A6), Functional Block Diagram

    TO 31R2-2TRC207-1 Figure 5-3. 15 Watt Power Amplifier Assembly (A1A6), Functional Block Diagram...

  • Page 55: Chapter 6 Maintenance

    TO 31R2-2TRC207-1 CHAPTER 6 MAINTENANCE GENERAL. This chapter provides organizational maintenance instructions for the bi-directional repeater. This includes operational checkout, inspection and preventive maintenance, troubleshooting, and removal/replacement procedures. OPERATIONAL CHECKOUT. Perform the procedures in paragraphs 6-2.1 through 6-2.5 to check the bi-directional repeater for normal operation. These checks should be performed when equipment is used for the first time, when the equipment has been damaged, or if the equipment has not been used for an extended period of time.

  • Page 56: 6-2.3 Radio A Tune Mode Verification

    TO 31R2-2TRC207-1 6-2.3 Radio A Tune Mode Verification. Verify functionality of receive mode as follows: Set the bi-directional repeater switches and controls as indicated in Table 6-2. Table 6-2. Initial Switch and Control Settings for Radio A Tune Mode Verification Switch/Control Position AC/DC POWER switch (1, Figure 4-2)

  • Page 57: Fault Led

    TO 31R2-2TRC207-1 Verify the green LED on Radio B receiver-transmitter is illuminated and the green LED on Radio A receiver-transmitter is not illuminated. 6-2.5 Fault LED. The red FAULT LED (2, Figure 4-1) on the front panel is illuminated either 1) when the power amplifier temperature is excessive, 2) if there is an RF path fault (the BDR or diplexer is cabled incorrectly, the diplexer is tuned incorrectly, or frequency spacing is less than the recommended minimum), or 3) Radio A has a fault or there is no radio in the Radio A sleeve.

  • Page 58: Troubleshooting

    TO 31R2-2TRC207-1 6-3.3.1 Inspection. Inspect the bi-directional repeater as follows: Inspect the equipment covers and front panel for condition of finish and panel markings. Inspect the unit for dents, punctures, or worn areas. Inspect external surfaces for loose or missing screws or washers. Inspect the receptacles and connectors for condition of pins, contacts, and mounting.

  • Page 59: Table 6-5. Organizational Maintenance Guide - Operator

    TO 31R2-2TRC207-1 Table 6-5. Organizational Maintenance Guide - Operator Symptom Possible Cause Remedy Repeater does not have any Failed power source Restore prime power lamps illuminated, and Failed batteries Replace batteries/check power source Failed Radio A Replace Radio A Repeater does not receive Failed Radio B Replace Radio B or transmit with power and...
  • Page 60 TO 31R2-2TRC207-1 Table 6-5. Organizational Maintenance Guide - Operator - CONT Symptom Possible Cause Remedy Repeater constantly transmits Bad or no programming Check receiver-transmitters for proper without valid signal frequency information - correct if required Failed Radio A Replace Radio A Failed Radio B Replace Radio B Failed BDR assembly...
  • Page 61 TO 31R2-2TRC207-1 Table 6-5. Organizational Maintenance Guide - Operator - CONT Symptom Possible Cause Remedy Mismatched receiver-transmitter Ensure same configuration of receiver- Repeater receive characteristics transmitter, diplexer, and antenna are are frequency sensitive; some but installed not all frequencies meet specified levels Failed Radio A Replace Radio A...

  • Page 62: Table 6-6. Organizational Maintenance Guide - Repair Specialist

    TO 31R2-2TRC207-1 Table 6-6. Organizational Maintenance Guide - Repair Specialist Symptom Possible Cause Remedy Repeater does not have any Failed repeater control CCA Remove and replace repeater control CCA lamps illuminated, and Fault cannot be isolated/repaired Return the BDR assembly to depot for Repeater does not receive at the repair specialist level repair...

  • Page 63: Removal/Replacement Procedures

    TO 31R2-2TRC207-1 Table 6-6. Organizational Maintenance Guide - Repair Specialist - CONT Symptom Possible Cause Remedy Repeater transmit characteristics Fault cannot be isolated/repaired Return the BDR assembly to depot for are frequency sensitive; some but at the repair specialist level repair not all frequencies meet specified levels...
  • Page 64 TO 31R2-2TRC207-1 6-5.1.1 Antenna Cable Removal/Replacement. Remove/replace antenna cable as follows: Disconnect the antenna cable from the Antenna connector on the power supply by turning counterclockwise. Disconnect the antenna cable from the connector at the base of the antenna mast by grasping the connector on the antenna cable and turning counterclockwise.

  • Page 65: Figure 6-1. Detail Of Diplexer Shock Mount Assembly

    TO 31R2-2TRC207-1 Remove the screws (22) holding the power supply mounting plate to the weldment frame (5). Slide the power supply to the right (as seen from the front) and lift the left edge of the mounting plate to clear the frame.

  • Page 66: 6-5.2 Removal/Replacement Procedures - Repair Specialist

    TO 31R2-2TRC207-1 Replace the diplexer with a known good diplexer for the same frequency band. When replacing the diplexer, ensure that the mounting holes on the bottom of the diplexer are aligned with the correct holes on the frame so that the front of the diplexer is at the front of the frame. Reconnect the coaxial cables to the diplexer: W3 to TX, W2 to RX, and W4 to ANT.
  • Page 67 TO 31R2-2TRC207-1 6-5.2.3 15 Watt Power Amplifier Assembly (A6) (SS-4100853-501) Removal/Replacement. Remove/replace the power amplifier (PA) assembly (A1A6) as follows: Place the bi-directional repeater upside down. Remove the bi-directional repeater bottom cover. Pull clamps away from connector on J4 on parent board. Remove connector of amplifier control cable assembly (A6W1).

  • Page 69: Chapter 7 Illustrated Parts Breakdown

    TO 31R2-2TRC207-1 CHAPTER 7 ILLUSTRATED PARTS BREAKDOWN Section I. INTRODUCTION GENERAL The Illustrated Parts Breakdown (IPB) lists, illustrates, and describes the parts used in the BDR, Radio Set AN/TRC- 6728. The items are manufactured by Racal Communications, Inc., Rockville, Maryland. MAINTENANCE PARTS LIST The Maintenance Parts List (MPL), (Section II), consists of the complete systems divided into main groups.

  • Page 70: Numerical Index

    TO 31R2-2TRC207-1 Description Column. This column contains the description of all items appearing on the MPL. The indentation headed "1" through "7" consists of the approved item name, as found in the Federal Item Identification Guide for Supply Catalog Handbook H6-1, or is in accordance with the contractor's drawing title.

  • Page 71: Reference Designation Index

    TO 31R2-2TRC207-1 AN931-4-13 16.W2 A2460 16W060 A317 1140 32P010.1 121873 32P0101 Figure and Index Number Column. For each part number, the figure or figure and index number refers to the MPL where the parts relationship is shown. When an assembly or part has not been assigned an index number, the figure and index number of the preceding part in the MPL is used with the letter "F"...

  • Page 72: Cage Code Summary

    TO 31R2-2TRC207-1 CAGE CODE SUMMARY CAGE Code Manufacturer 1BZ19 C and S Antennas, Inc. 05972 Loctite Corp. 07700 Technical Wire Products, Inc. 13074 Multi-Flex Seals, Inc. 23386 Racal Communications, Inc. 23657 Shakespeare Co. 27264 Molex Inc. 52437 Bretford MFG, Inc. 73734 Federal Screw Products, Inc.
  • Page 73 TO 31R2-2TRC207-1 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN...
  • Page 74 TO 31R2-2TRC207-1 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN...
  • Page 75 TO 31R2-2TRC207-1 This Page Left Blank Intentionally...

  • Page 76: Section Ii. Maintenance Parts List

    TO 31R2-2TRC207-1 Section II. MAINTENANCE PARTS LIST Figure 7-1. Radio Set AN/TRC-207 (Sheet 1 of 2)
  • Page 77 TO 31R2-2TRC207-1 Figure 7-1. Radio Set AN/TRC-207 (Sheet 2 of 2)

  • Page 78: Table 7-1. Radio Set An/Trc-207

    31R2-2TRC207-1 TO 31R2-2TRC207-1 Table 7-1. Radio Set AN/TRC-207 Figure & Description Units per Usable Part Number CAGE SMR Code Index No. 1 2 3 4 5 6 7 Assy on Code 4101025-501 23386 Radio Set AN/TRC-207 ......0001 PEODDS (refer to Figure 7-1 for breakdown)
  • Page 79 TO 31R2-2TRC207-1 Figure & Description Units per Usable Part Number CAGE SMR Code Index No. 1 2 3 4 5 6 7 Assy on Code 7-1-20 MS51958-73 96906 @ Screw, Machine.......... 0024 PAOZZN (23386/SS-77776) (SPEC CTRL DRW) 7-1-21 4101028-501 23386 @ Power Supply ..........0001 PAOLDT (A2)
  • Page 80 TO 31R2-2TRC207-1 Figure & Description Units per Usable Part Number CAGE SMR Code Index No. 1 2 3 4 5 6 7 Assy on Code 7-1-39 SP10SS 1BZ19 @ Mast Kit, Tactical Repeater ....... 0001 PAOZZN (23386/SS-1600281-1) (SPEC CTRL DRW) 7-1-39a SL/33644 1BZ19 $ $ Antenna Adapter ........

  • Page 81: Figure 7-2. Bi-Directional Repeater Assembly (4101027-501) (Sheet 1 Of 3)

    TO 31R2-2TRC207-1 Figure 7-2. Bi-Directional Repeater Assembly (4101027-501) (Sheet 1 of 3) 7-13...
  • Page 82 TO 31R2-2TRC207-1 Figure 7-2. Bi-Directional Repeater Assembly (4101027-501) (Sheet 2 of 3) 7-14...
  • Page 83 TO 31R2-2TRC207-1 Figure 7-2. Bi-Directional Repeater Assembly (4101027-501) (Sheet 3 of 3) 7-15...

  • Page 84: Table 7-2. Bi-Directional Repeater Assembly (4101027-501)

    TO 31R2-2TRC207-1 Table 7-2. Bi-Directional Repeater Assembly (4101027-501) Figure & Description Units per Usable Part Number CAGE SMR Code Index No. 1 2 3 4 5 6 7 Assy on Code 4101027-501 23386 Bi-directional Repeater Assembly ....0001 PAOLDT (refer to Figure 7-2 for breakdown) (ESD) 7-2-1 SS-4100823-502 23386 @ Sleeve Assembly, Short ......
  • Page 85 TO 31R2-2TRC207-1 Figure & Description Units per Usable Part Number CAGE SMR Code Index No. 1 2 3 4 5 6 7 Assy on Code 7-2-22 NAS671C4 80205 Nut, Plain Hex.......... 0004 PADZZN (23386/75203)(SPEC CTRL DRW) 7-2-23 SS-4100878-501 23386 @ Cover Assy, Bottom ......... 0001 7-2-24 SS-4400219-1...
  • Page 86 TO 31R2-2TRC207-1 This Page Left Blank Intentionally 7-18...

  • Page 87: Figure 7-3. Power Amplifier Assembly, 15W (Ss-4100853-501)

    TO 31R2-2TRC207-1 Figure 7-3. Power Amplifier Assembly, 15W (SS-4100853-501) 7-19...

  • Page 88: Table 7-3. Power Amp Assembly, 15W (Ss-4100853-501)

    TO 31R2-2TRC207-1 Table 7-3. Power AMP Assembly, 15W (SS-4100853-501) Figure & Description Units per Usable Part Number CAGE SMR Code Index No. 1 2 3 4 5 6 7 Assy on Code SS-4100853-501 23386 Power Amplifier Assy, 15W (ESD).... 0001 PAOLDT 96906 @ Screw, Machine ........
  • Page 89 TO 31R2-2TRC207-1 Section III. NUMERICAL INDEX Figure & Figure & Figure & Part Number Part Number Part Number Index No. Index No. Index No. 1026-250-SS-26 7-3-2 AN960-C4 7-3-9 MS51957-84 7-1-10 1055-SS 7-3-4 AN960-C4 7-2-19 MS51957-85 7-1-35 107-SS-26 7-3-3 AR31EF 7-1-39d MS51957-87 7-1-22 2500145-502...
  • Page 90 TO 31R2-2TRC207-1 Figure & Figure & Figure & Part Number Part Number Part Number Index No. Index No. Index No. 9268-A257-16 7-1-28 SS-3500292-505 7-1-31 SS-4400225-1 7-1-5 (W4) 9286-A194-16AB 7-1-18 SS-4100730-501 7-2-30 SS-4400226-1 7-2-11 (A1) MS51957-28 7-2-28 SS-4100807-512 7-1-2 SS-4500107-501 7-1-47 (A4, A5) (W9) MS51957-79...

  • Page 91: Figure 1-1. Radio Set An/Trc-207

    TO 31R2-2TRC207-1 Section IV. REFERENCE DESIGNATION INDEX Reference Designator Figure & Item Reference Designator Figure & Item Reference Designator Figure & Item Number Number Number Radio Set AN/TRC-207 7-1-REF 7-2-3 7-1-1 7-2-12 7-1-21 7-2-14 7-1-33 7-3-7 7-1-33 7-1-33 A4,A5 7-1-2...
  • Page 92 TO 31R2-2TRC207-1 Section V. COMMON BULK ITEMS LIST Part Number CAGE Code Description Unit of Measure No 222 50CC 05972 Threadlocking Compound No. 222 (23386/91172) 7-24...

  • Page 93: Chapter 8 Circuit Diagrams

    TO 31R2-2TRC207-1 CHAPTER 8 CIRCUIT DIAGRAMS SCOPE This chapter contains the following diagram: Figure No. Title Radio Set AN/TRC-207, Interconnection Diagram 8-1/(8-2 blank)
  • Page 94 TO 31R2-2TRC207-1...

  • Page 95: Figure 8-1. Radio Set An/Trc-207, Interconnection Diagram

    TO 31R2-2TRC207-1 Figure 8-1. Radio Set AN/TRC-207, Interconnection Diagram 8-3/(8-4 blank)

  • Page 97: Glossary

    TO 31R2-2TRC207-1 GLOSSARY Alternating current Automatic level control Antenna ASSY Assembly Bi-directional Repeater Celsius (centigrade) Circuit card assembly Controlled cryptographic item Clear Centimeter CTCSS Continuous tone-controlled squelch system CTRL Control Continuous wave Decibels Decibel (isotropic) Decibels relative to a 1/2 wavelength dipole Power in decibels (referenced to 1 milliwatt) Direct current Drawing...

  • Page 99: Alphabetical Index

    TO 31R2-2TRC207-1 ALPHABETICAL INDEX Paragraph, Figure, Subject or Table Number Antenna Assembly: Description P1-1.2.3 Removal and Replacement Procedures P6-5.1.2 Bi-directional repeater Assembly: Description P1-1.2.1, F7-2 Indicators, Controls, and Switches T4-1, F4-1 Removal and Replacement Procedures P6-5.6.7 Cables, Interconnecting T2-2 Capabilities and Limitations P1-3, T1-3 Control Panel Assembly (A5): Functional System Operation...
  • Page 100 TO 31R2-2TRC207-1 Paragraph, Figure, Subject or Table Number Functional Operation of Electronic Circuits Repeater Control CCA (A3) P5-3, F5-2 15 Watt Power Amplifier Assembly (A6) P5-4, F5-3 Functional System(s) Operation P5-2 AC/DC Power Supply (A2) P5-2.10 Antenna System P5-2.8 Control Panel (A5) P5-2.4 Diplexer P5-2.9...
  • Page 101 TO 31R2-2TRC207-1 Paragraph, Figure, Subject or Table Number Leading Particulars P1-2, T1-2 Operating Procedures: Covert Operations P4-6 Equipment Shutdown P4-8 Initial Power-Up and Diplexer Tuning P4-3 Receiver-Transmitters P4-7 Receiving Message P4-4 Transmitting Message P4-5 Operational Checkout: Display Off Control P6.2.2 Fault LED P6-2.5 Power-Up Verification...
  • Page 102 TO 31R2-2TRC207-1 Paragraph, Figure, Subject or Table Number Removal/Replacement Procedures Antenna P6-5.1.2 Antenna Cable P6-5.1.1 Control Panel Assembly (A5) P6-5.2.2 Diplexer P6-5.1.6 Power Cable P6-5.1.4 Power Supply P6-5.1.5 Receiver-Transmitter P6-5.1.3 Repeater Control CCA (A2) P6-5.2.1 Bi-directional repeater Assembly P6-5.1.7 15 Watt Power Amplifier Assembly (A6) P6-5.2.3 Repeater Control CCA (A2): Functional Operation of Electronic Circuits...

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