GDL 59 Data Link Installation Manual

190-00837-00

August, 2010

Revision C

© Copyright 2010 Garmin Ltd. or its subsidiaries All Rights Reserved Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, disseminated, downloaded or stored in any storage medium, for any purpose without the express prior written consent of Garmin. Garmin hereby grants permission to download a single copy of this manual and of any revision to this manual onto a hard drive or other electronic storage medium to be viewed and to print one copy of this manual or of any revision hereto, provided that such electronic or printed copy of this manual or revision must contain the complete text of this copyright notice and provided further that any unauthorized commercial distribution of this manual or any revision hereto is strictly prohibited. Garmin International, Inc. 1200 E. 151st Street Olathe, KS 66062 USA Telephone: 913.397.8200 Aviation Panel-Mount Technical Support Line (Toll Free) 1.888.606.5482 www.garmin.com Garmin (Europe) Ltd. Liberty House, Bulls Copse Road Hounsdown Business Park Southampton, SO40 9RB U.K. +44/ (0) 870.8501241 Garmin AT, Inc. 2345 Turner Rd., SE Salem, OR 97302 USA Telephone: 503.581.8101

RECORD OF REVISIONS Revision Revision Date Description A 04/09/08 Initial Release B 07/06/09 Corrrected interconnect drawing and added ETSO info C 08/17/10 Added Flight Data Services activation information

DOCUMENT PAGINATION Section Table of Contents Section 1 Section 2 Section 3 Section 4 Appendix A Appendix B Page A Revision C

Page Range i–iv 1-1–1-8 2-1–2-2 3-1–3-6 4-1–4-6 A-1–A-8 B-1–B-2 GDL 59 Installation Manual 190-00837-00

INFORMATION SUBJECT TO EXPORT CONTROL LAWS This document may contain information which is subject to the Export Administration Regulations ("EAR") issued by the United States Department of Commerce (15 CFR, Chapter VII, Subchapter C) and which may not be exported, released, or disclosed to foreign nationals inside or outside of the United States without first obtaining an export license. The preceding statement is required to be included on any and all reproductions in whole or in part of this manual.

WARNING This product, its packaging, and its components contain chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. This Notice is being provided in accordance with California's Proposition 65. If you have any questions or would like additional information, please refer to our web site at www.garmin.com/prop65.

WARNING Perchlorate Material – special handling may apply, See www.dtsc.ca.gov./hazardouswaste/perchlorate.

CURRENT REVISION DESCRIPTION Revision C

Page Number(s) 1-5 1-7 3-6

GDL 59 Installation Manual 190-00837-00

Section Number 1.4.5 1.5.3 3.8

Description of Change Added new Wi-Fi info Added 802.11 info to Table 1-9 Added Flight Data Services activation info

Page i Revision C

TABLE OF CONTENTS PARAGRAPH

PAGE

1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7

GENERAL DESCRIPTION 1-1 Introduction........................................................................................................................................1-1 Equipment Description ......................................................................................................................1-1 Interface Summary.............................................................................................................................1-2 Technical Specifications ....................................................................................................................1-3 Certification .......................................................................................................................................1-5 Reference Documentation..................................................................................................................1-7 Limited Warranty...............................................................................................................................1-8

2. 2.1 2.2 2.3 2.4 2.5 2.6

INSTALLATION 2-1 Introduction........................................................................................................................................2-1 Installation Materials .........................................................................................................................2-1 Equipment Available .........................................................................................................................2-1 Cabling and Wiring............................................................................................................................2-1 Cooling Air ........................................................................................................................................2-2 Mounting Requirements ....................................................................................................................2-2

3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

INSTALLATION PROCEDURE 3-1 Unpacking Unit..................................................................................................................................3-1 Wiring Harness Installation ...............................................................................................................3-1 Wi-Fi Antenna Installation ................................................................................................................3-2 Coaxial Cable Installation..................................................................................................................3-4 Backshell Assembly and Installation .................................................................................................3-5 Final Installation ................................................................................................................................3-5 Post Installation Configuration and Checkout ...................................................................................3-6 Activation of Garmin Flight Data Services .......................................................................................3-6 Continued Airworthiness ...................................................................................................................3-6

4. 4.1 4.2 4.3 4.4 4.5

SYSTEM INTERCONNECTS 4-1 Pin Function List................................................................................................................................4-1 Power Functions ................................................................................................................................4-3 Installation Selection Pins..................................................................................................................4-3 Serial Data .........................................................................................................................................4-4 Audio Connections ............................................................................................................................4-6

APPENDIX A OUTLINE AND INSTALLATION DRAWINGS APPENDIX B INTERCONNECT DRAWING

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GDL 59 Installation Manual 190-00837-00

LIST OF ILLUSTRATIONS FIGURE 1-1 1-2 2-1 3-1 A-1 A-1 A-2 A-2 B-1

PAGE

GDL 59 Unit View ............................................................................................................................1-1 GDL 59 Block Diagram.....................................................................................................................1-2 GDL 59 Modular Unit Rack ..............................................................................................................2-2 TNC Connector Installation...............................................................................................................3-4 GDL 59 Modular Rack Outline Drawing (Sheet 1 of 2)................................................................... A-1 GDL 59 Modular Rack Outline Drawing (Sheet 2).......................................................................... A-3 GDL 59 Stand-alone Rack Outline Drawing (Sheet 1 of 2) ............................................................. A-5 GDL 59 Stand-alone Rack Outline Drawing (Sheet 2) .................................................................... A-7 GDL 59 Example Interconnect ......................................................................................................... B-1

LIST OF TABLES TABLE

PAGE

1-1 Unit with Modular Rack ....................................................................................................................1-3 1-2 Unit with Stand-alone Rack...............................................................................................................1-4 1-3 Input Voltage .....................................................................................................................................1-4 1-4 Maximum Current Specifications ......................................................................................................1-4 1-5 General Specifications .......................................................................................................................1-4 1-6 Wi-Fi Antenna Minimum Requirements ...........................................................................................1-5 1-7 TSO/ETSO Authorizations ................................................................................................................1-6 1-8 TSO/ETSO Deviations ......................................................................................................................1-6 1-9 Non-TSO Functions...........................................................................................................................1-7 1-10 Referenced Publications ....................................................................................................................1-7 2-1 Unit Part Number...............................................................................................................................2-1 2-2 Accessories ........................................................................................................................................2-1 3-1 Pin Contact Part Numbers..................................................................................................................3-1 3-2 Recommended Crimp Tools ..............................................................................................................3-1

GDL 59 Installation Manual 190-00837-00

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GDL 59 HARDWARE MOD LEVEL HISTORY The following table identifies hardware modification (Mod) Levels for the GDL 59. Mod Levels are listed with the associated service bulletin number, service bulletin date, and the purpose of the modification. The table is current at the time of publication of this manual (see date on front cover) and is subject to change without notice. Authorized Garmin Sales and Service Centers are encouraged to access the most up-to-date bulletin and advisory information on the Garmin Dealer Resource web site at www.garmin.com using their Garmin-provided user name and password. MOD LEVEL

Page iv Revision C

SERVICE BULLETIN NUMBER

SERVICE BULLETIN DATE

PURPOSE OF MODIFICATION

GDL 59 Installation Manual 190-00837-00

1 GENERAL DESCRIPTION 1.1

Introduction

This manual presents mechanical and electrical installation requirements for installing the GDL 59 as part of the Garmin Integrated Flight Deck. The GDL 59 can be integrated into a variety of airframes under an appropriate TC or STC. Each installation may vary. Use only approved (type or supplemental type) data for specific installation instructions in a particular aircraft.

Figure 1-1. GDL 59 Unit View

1.2

Equipment Description

The GDL 59 provides a POTS (plain old telephone service) phone interface, a flight parameter data logger, and a high speed data link between the aircraft systems and ground computers while the aircraft is on the ground using the IEEE 802.11g (“Wi-Fi”) protocol. The GDL 59 also provides two interfaces to an optional GSR 56, which adds airborne low speed data link and voice communication capability.

GDL 59 Installation Manual 190-00837-00

Page 1-1 Revision C

1.3

Interface Summary

The GDL 59 unit interfaces to the Garmin Integrated Flight Deck using HSDB. The GDL 59 can be installed with zero, one, or two GSR 56 units. Installation will vary between airframes.

WiFi

Iridiu m Ethernet

RS-232

Ethernet

Iridium Audio

Ethernet

GSR 56 (Optional)

Passenger Computers

Iridiu m

HSDB

GDL 59

RS-232 Iridium Audio

GSR 56 (Optional)

GDU 1XXX (or GDL 69A or GSD 41) Audio

HSDB

Audio Panel(s) Other Avionics

POTS

Hand set

Figure 1-2. GDL 59 Block Diagram

Page 1-2 Revision C

GDL 59 Installation Manual 190-00837-00

1.3.1

I/O

The GDL 59 supports the following I/O: • Audio Panel I/O: The GDL 59 provides one differential audio I/O channel for interfacing to the audio panel(s). •

Avionics HSDB: The GDL 59 provides two HSDB ports. One port must be used to connect the GDL 59 to the core Garmin Integrated Flight Deck system via a spare GDU 1XXX, GSD 41, or GDL 69A HSDB port. The other port is available for possible future avionics expansion.

•

Iridium Audio I/O: The GDL 59 provides two differential audio I/O channels to carry Iridium telephone audio to and from the GSR 56 Iridium transceiver(s).

•

Analog POTS Interface: The GDL 59 provides a POTS (plain old telephone service) interface that allows a standard analog telephone to interface to the GDL 59. Up to two POTS telephones can be connected to this interface in parallel.

NOTE To simplify operation of the telephone, Garmin recommends using a POTS telephone that does not have a Hold button. •

RS-232 I/O: The GDL 59 has two RS-232 ports. RS-232 is the primary communication path between the GDL 59 and the GSR 56 units.

•

Ethernet Ports: The GDL 59 provides three 10/100 Base T Ethernet ports that are compliant with IEEE 802.3 standards. These ports can be used to provide connection to an Electronic Flight Bag (EFB), or for other future options.

1.4

Technical Specifications

It is the responsibility of the installing agency to obtain the latest revision of the GDL 59 Environmental Qualification Form. This form is available directly from Garmin under the following part number: GDL 59 Environmental Qualification Form, Garmin part number 005-00431-10 To obtain a copy of this form, see the dealer/OEM portion of the Garmin web site (www.garmin.com).

1.4.1

Physical Characteristics Table 1-1. Unit with Modular Rack Characteristic

Width Height Depth (Rack w/ Connectors) Unit Weight (GDL 59) Unit (GDL 59) and Modular Rack Weight

GDL 59 Installation Manual 190-00837-00

Specification 1.23 inches (3.12 cm) 6.30 inches (16.00 cm) 9.07 inches (23.04 cm) 1.5 lb (0.68 kg) 2.3 lb (1.04 kg)

Page 1-3 Revision C

Table 1-2. Unit with Stand-alone Rack Characteristic

Specification

Width Height Depth (Rack w/ Connectors) Unit Weight (GDL 59) Unit (GDL 59) and Stand-alone Rack Weight

1.4.2

1.47 inches (3.73 cm) 6.91 inches (17.55 cm) 9.13 inches (23.19 cm) 1.5 lb (0.68 kg) 2.7 lb (1.22 kg)

Power Requirements Table 1-3. Input Voltage Characteristic

Input Voltage

Specification 14/28 Vdc See the Environmental Qualification Form for details on surge ratings and minimum/maximum operating voltages. Table 1-4. Maximum Current Specifications

Unit Status

Max Current @ 28 Vdc

Off* 0.100 A On 0.572 A *DATA LINK REMOTE PWR OFF in active state

Max Current @ 14 Vdc 0.100 A 1.15 A

NOTE The GDL 59 is not certified for use on the emergency power bus.

NOTE During the first five seconds of unit power-up, current is slightly higher due to backup capacitors being charged. Estimate initial power-up current to be ~150 mA @ 28 Vdc higher or ~300 mA @ 14 Vdc higher than the above figures.

1.4.3

General Specifications Table 1-5. General Specifications Characteristics

Operating Temperature Range Humidity Altitude Range Software Compliance Maximum Average Power Input from Antenna Maximum Peak Power (1% Duty Cycle) Input from Antenna

Page 1-4 Revision C

Specifications -55 to +70 °C. For more details see Environmental Qualification Form 95% non-condensing -1,500 ft to 55,000 ft RTCA/DO-178B Level D and E +15 dBm +30 dBm

GDL 59 Installation Manual 190-00837-00

1.4.4

General Antenna Requirements

Garmin recommends the Wi-Fi antenna specifications shown in Table 1-6. These antenna specifications are approved with the certification of the GDL 59. Any Wi-Fi antenna with specifications listed in the following table should work with the GDL 59. Table 1-6. Wi-Fi Antenna Minimum Requirements Characteristics Frequency Range Gain (Typical) Nominal Output Impedance Operating Temperature Gain

Specifications 2412 to 2484 MHz 100k ohms (inactive) b) High: 8 VDC < Vin < 36 VDC (active) Pin Name DATA LINK REMOTE POWER OFF

4.3 4.3.1

Connector P591

Pin 75

I/O In

Connector P591 P591

Pin 56 76

I/O In In

Installation Selection Pins Iridium Status Inputs

Pin Name IRIDIUM 1 STATUS DISCRETE* IN IRIDIUM 2 STATUS DISCRETE* IN

GDL 59 Installation Manual 190-00837-00

Page 4-3 Revision C

4.3.2

Remote Power On

These outputs are used to power on or off GSR 56 units used in the installation. DISCRETE OUT* pins: INACTIVE: Floating (can be pulled up to externally sourced Vout in the range 0 ≤ Vout ≤ 33VDC) Leakage current in the INACTIVE state is typically ≤ 10 uA to ground ACTIVE: Vout ≤ 0.5VDC with ≤ 20 mA sink current Sink current must be externally limited to 20 mA max Pin Name IRIDIUM 1 REMOTE POWER ON* IRIDIUM 2 REMOTE POWER ON* • Denotes Active Low (Ground to activate)

4.4

Connector P591 P591

Pin 73 74

I/O Out Out

Serial Data

4.4.1

Avionics Ethernet HSDB

The GDL 59 has two Ethernet based high speed data busses (HSDB) that are used to interface with other LRUs in the Garmin Integrated Flight Deck system. These busses meet the hardware aspects of IEEE standard 802.3 for 10/100 Base T Ethernet communications. Pin Name AVIONICS ETHERNET IN 1 A AVIONICS ETHERNET IN 1 B AVIONICS ETHERNET OUT 1 A AVIONICS ETHERNET OUT 1 B AVIONICS ETHERNET IN 2 A AVIONICS ETHERNET IN 2 B AVIONICS ETHERNET OUT 2 A AVIONICS ETHERNET OUT 2

Page 4-4 Revision C

Connector P591 P591 P591 P591 P591 P591 P591 P591

Pin 10 30 9 29 4 24 3 23

I/O In In Out Out In In Out Out

GDL 59 Installation Manual 190-00837-00

4.4.2

User Ethernet

The GDL 59 has three Ethernet data busses that meet the hardware aspects of IEEE standard 802.3 for 10/100 Base T Ethernet communications.

NOTE Garmin recommends leaving USER ETHERNET 3 unconnected, as it may be used for other functions in the future. Pin Name USER ETHERNET IN 3 A USER ETHERNET IN 3 B USER ETHERNET OUT 3 A USER ETHERNET OUT 3 B USER ETHERNET IN 4 A USER ETHERNET IN 4 B USER ETHERNET OUT 4 A USER ETHERNET OUT 4 B USER ETHERNET IN 5 A USER ETHERNET IN 5 B USER ETHERNET OUT 5 A USER ETHERNET OUT 5 B 4.4.3

Connector P591 P591 P591 P591 P591 P591 P591 P591 P591 P591 P591 P591

Pin 6 26 5 25 8 28 7 27 2 22 1 21

I/O In In Out Out In In Out Out In In Out Out

RS-232 Serial Input/Output

The RS-232 outputs conform to EIA/TIA-232C with an output voltage swing of at least ±5 V when driving a standard RS-232 load. RS-232 Channels 1 and 2 are to be used for communication with optional GSR 56 units (if installed). Pin Name RS-232 OUT 1 RS-232 IN 1 RS-232 OUT 2 RS-232 IN 2

GDL 59 Installation Manual 190-00837-00

Connector P591 P591 P591 P591

Pin 63 64 65 66

I/O Out In Out In

Page 4-5 Revision C

4.4.4

Handset POTS (Plain Old Telephone Service) Input/Output

The POTS interface shall: 1) Be capable of detecting a hook-switch flash signal where the on-hook time is 200ms. 2) Be capable of detecting an on-hook condition where on-hook is represented by a load of 10K Ω or greater between the tip and ring leads. 3) Deliver an on-hook voltage between -42 and -56 VDC into a 1M Ω or greater load. 4) Be capable of delivering a power ring signal with a frequency between 15 Hz and 68 Hz and amplitude between 40 and 120 Vrms into a 2.3K Ω +/- 10% load. 5) Maintain a source current of 25mA +/- 5% into an off-hook load. Up to two analog POTS handsets may be connected to these lines. Pin Name POTS HANDSET RING POTS HANDSET TIP

4.5

Connector P591 P591

Pin 59 78

I/O I/O I/O

Audio Connections

4.5.1

Iridium Audio Channels

The Iridium Audio channels interface with the GSR 56 units. See Appendix B for sample interconnect drawing. Pin Name IRIDIUM AUDIO IN 1 HI IRIDIUM AUDIO IN 1 LO IRIDIUM AUDIO OUT 1 HI IRIDIUM AUDIO OUT 1 LO IRIDIUM AUDIO IN 2 HI IRIDIUM AUDIO IN 2 LO IRIDIUM AUDIO OUT 2 HI IRIDIUM AUDIO OUT 2 LO 4.5.2

Connector P591 P591 P591 P591 P591 P591 P591 P591

Pin 15 34 16 35 13 32 14 33

I/O In In Out Out In In Out Out

Pin 19 38 20 39 17 36 18 37

I/O In In Out Out In In Out Out

Audio System Channels

The Audio System channels connect to other LRUs, such as the GMA Audio Panel. Pin Name AUDIO SYSTEM 1 AUDIO IN HI AUDIO SYSTEM 1 AUDIO IN LO AUDIO SYSTEM 1 AUDIO OUT HI AUDIO SYSTEM 1 AUDIO OUT LO AUDIO SYSTEM 2 AUDIO IN HI AUDIO SYSTEM 2 AUDIO IN LO AUDIO SYSTEM 2 AUDIO OUT HI AUDIO SYSTEM 2 AUDIO OUT LO

Connector P591 P591 P591 P591 P591 P591 P591 P591

NOTE For best noise immunity, it is recommended to connect AUDIO SYTEM 2 AUDIO OUT (pins 18 and 37) to a differential input only. Page 4-6 Revision C

GDL 59 Installation Manual 190-00837-00

APPENDIX A

OUTLINE AND INSTALLATION DRAWINGS

MODULAR INSTALLATION

1.23 31.1 .6 15

4X NOTE 3

ANTENNA

7.26 184.4 6.300 160.02

6.900 175.26 TYP

J591 3.0 76

.36 9.1 TYP

4X NOTE 3

.480 12.19

4.3 109 9.07 230.4

.480 12.19 TYP .480 12.19 TYP

.360 9.14 TYP

4X NOTE 3

NOTES: 1. DIMENSIONS: INCHES[mm] 2. DIMENSIONS ARE SHOWN FOR REFERENCE ONLY. 3. MOUNTING HOLE FOR #6 FLAT HEAD 100 CSK SCREW (12 PLCS)

.377 9.58 TYP 3.727 94.67 TYP

Figure A-1. GDL 59 Modular Rack Outline Drawing (Sheet 1 of 2) GDL 59 Installation Manual 190-00837-00

Page A-1 (Page A-2 Blank) Revision C

APPENDIX A

OUTLINE AND INSTALLATION DRAWINGS

PART OF NUTPLATE KIT 011-00915-00 8 PLCS

BACK PLATE KIT 011-00796-02 MODULAR RACK 115-00411-00

GDL 59 011-01746-00

CONNECTOR KIT 011-01760-00

PART OF CONNECTOR KIT 011-01760-00 2 PLCS

NUTPLATE KIT 011-00915-00 (PREFERRED WITH GARMIN SYSTEM RACK) OR 011-01148-00 (NOT SHOWN)

Figure A-1. GDL 59 Modular Rack Outline Drawing (Sheet 2) GDL 59 Installation Manual 190-00837-00

Page A-3 (Page A-4 Blank) Revision C

APPENDIX A

OUTLINE AND INSTALLATION DRAWINGS

STANDALONE INSTALLATION

7.910 200.91

2X 1.47 37.3

2X 1.63 41.3

2X 1.125 28.58

.7 19

.58 14.7 TYP

2X 4.500 114.30

4X NOTE 3

4X NOTE 3

2X 4.500 114.30

5.125 130.17 TYP

ANTENNA

J591

8.710 221.23

2X 6.914 175.62 3X 6.426 163.22

2X 1.60 40.5

4.0 101

9.13 231.9

3.6 91 NOTES: 1. DIMENSIONS: INCHES[mm] 2. DIMENSIONS ARE SHOWN FOR REFERENCE ONLY. 3. MOUNTING HOLE FOR #6 FLAT HEAD 100 CSK SCREW (8 PLCS) 4. MOUNTING HOLE FOR #8 PAN HEAD SCREW (4 PLCS)

2X 4.458 113.22

2X .37 9.4

2X .728 18.49 4X NOTE 4

Figure A-2. GDL 59 Stand-alone Rack Outline Drawing (Sheet 1 of 2) GDL 59 Installation Manual 190-00837-00

Page A-5 (Page A-6 Blank) Revision C

APPENDIX A

OUTLINE AND INSTALLATION DRAWINGS

STANDALONE INSTALLATION

BACK PLATE KIT 011-00796-02

CONNECTOR KIT 011-01760-00

PART OF CONNECTOR KIT 011-01760-00 2 PLCS STANDALONE RACK 115-00658-00

GDL 59 011-01746-00

Figure A-2. GDL 59 Stand-alone Rack Outline Drawing (Sheet 2) GDL 59 Installation Manual 190-00837-00

Page A-7 (Page A-8 Blank) Revision C

APPENDIX B

INTERCONNECT DRAWING GDL 59 DATALINK

P591

AUDIO SYSTEM 1 IN HI

19

AUDIO SYSTEM 1 IN LO

38

GMA 1347 AUDIO PANEL

1P3471 WHT BLU

WHT BLU

23 62

TEL MIC AUDIO OUT HI TEL MIC AUDIO OUT LO

42 43

TEL AUDIO IN HI TEL AUDIO IN LO

S

AUDIO SYSTEM 1 OUT HI

20

AUDIO SYSTEM 1 OUT LO

39

WHT BLU

WHT BLU

S

AIRCRAFT POWER 1 AIRCRAFT POWER 1 POWER GROUND POWER GROUND

71 72 52 53

1A

SEE NOTE 8

AVIONICS ETHERNET IN 1 B

30

AVIONICS ETHERNET IN 1 A

10

AVIONICS ETHERNET OUT 1 B

29

AVIONICS ETHERNET OUT 1 A

9

GDL 69A DATA LINK

P691

SEE NOTE 7

32 33 30 31

ETHERNET OUT 3 B ETHERNET OUT 3 A ETHERNET IN 3 B ETHERNET IN 3 A

S

HANDSET 1 POTS HANDSET TIP

78

POTS HANDSET RING

59

WHT BLU

TIP RING

S

NO.1 GSR56 TRANSCEIVER

1P561

IRIDIUM 1 STATUS DISCRETE* IN

56

31

STATUS DISCRETE

IRIDIUM 1 REMOTE POWER ON*

73

16

REMOTE POWER ON

IRIDIUM AUDIO OUT 1 HI

16 35

4 5

AUDIO IN HI AUDIO IN LO

1

AUDIO OUT HI

2

AUDIO OUT LO

IRIDIUM AUDIO OUT 1 LO

WHT BLU

WHT BLU

S

IRIDIUM AUDIO IN 1 HI IRIDIUM AUDIO IN 1 LO

15 34

WHT BLU

WHT BLU S

8

RS 232 OUT 1 SIGNAL GROUND RS 232 IN 1

63 44 64

WHT BLU ORN

WHT BLU ORN

13 14 12

RS-232 IN SIGNAL GROUND RS-232 OUT

P592

WI-FI ANTENNA

Figure B-1. GDL 59 Example Interconnect GDL 59 Installation Manual 190-00837-00

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