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TO 31R2-2TRC199-1

OPERATION AND MAINTENANCE INSTRUCTIONS

WITH ILLUSTRATED PARTS BREAKDOWN

ORGANIZATIONAL LEVEL

RADIO SET

AN/TRC-199

(TACTICAL 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 June, 1993.  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 JUNE 1993

CHANGE 1 - 10 AUGUST 1994

Summary of Contents for AN/TRC-199

Page 1: ...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 se...

Page 2: ...UNE 1993 CHANGE 1 10 AUGUST 1994 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 108 CONSISTING OF THE FOLLOWING Page Change No No Page Change No No Page Change No No Title page 1 A 1 B 1 i 0 ii 1 iii 0...

Page 3: ...TO 31R2 2TRC199 1 B Change 1 RECORD OF CHANGES CHANGE NO DATE TITLE OR BRIEF DESCRIPTION ENTERED BY 1 10 August 1994...

Page 4: ......

Page 5: ...SUPPORTING STRUCTURES 2 4 Section II INSTALLATION PROCEDURES 2 5 2 9 SPECIAL TOOLS AND EQUIPMENT REQUIRED FOR FIELD INSTALLATION 2 5 2 10 INSTALLATION SEQUENCE 2 5 2 10 1 Antenna Mast Installation 2...

Page 6: ...5 1 5 2 2 Repeater Control Circuit Card Assembly CCA A3 5 1 5 2 3 Parent Board Circuit Card Assembly CCA A4 5 1 5 2 4 Control Panel A5 5 1 5 2 5 RF Power Amplifier Assembly A6 5 1 5 2 6 28V DC DC Con...

Page 7: ...MERICAL INDEX 7 2 7 4 REFERENCE DESIGNATION INDEX 7 3 7 5 ELECTROSTATIC DISCHARGE ESD SENSITIVE DEVICES 7 3 7 6 CAGE CODE SUMMARY 7 4 Section II MAINTENANCE PARTS LISTS 7 10 Section III NUMERICAL INDE...

Page 8: ...gure 7 3 Power Amp Assembly 15W SS 4100853 501 7 19 FO 1 Radio Set AN TRC 199 Interconnection Diagram FP 1 LIST OF TABLES Table 1 1 Tactical Repeater Configurations by Frequency Band 1 3 Table 1 2 Lea...

Page 9: ...cuit before touching it RESUSCITATION Personnel working with or near high voltages should be familiar with modern methods of resuscitation Such information may be obtained from the Director of Base Me...

Page 10: ...ge 6 11 WARNING This equipment is capable of generating RF power sufficient to cause RF burns During transmit care should be taken to eliminate the possibility of touching exposed RF output points suc...

Page 11: ...nd pins When removing an assembly be sure to pull it straight out from the equipment Do not cock twist pry or carelessly jerk an electronic assembly to remove it from the mounting or connector 3 4 CAU...

Page 12: ......

Page 13: ...it operation and maintenance personnel to prepare the equipment for use including reference to post installation checkout procedures preparing the unit for reshipment packing handling and storage proc...

Page 14: ...10 Antenna 30 88 MHz 11 Antenna 136 174 MHz 12 Antenna 403 470 MHz 13 Antenna Mast TR 14 Case Transceiver Module 15 Strap Assembly Ground W5 16 Strap Assembly Ground W6 17 Strap Assembly Ground W7 18...

Page 15: ...TO 31R2 2TRC199 1 1 1 Figure 1 1 Radio Set AN TRC 199 Sheet 2 of 3...

Page 16: ...TO 31R2 2TRC199 1 1 2 Figure 1 1 Radio Set AN TRC 199 Sheet 3 of 3...

Page 17: ...external power supply and the plug in receiver transmitters The receiver transmitters plug into sleeves A8 A9 located on the left and right sides of the front panel of the tactical repeater assembly T...

Page 18: ...enna and less than 3 0 dB between the receive port and the antenna The diplexer is capable of handling 60 watts of radio frequency RF power in the transmit path and provides protection at the receive...

Page 19: ...container that can hold either four Lithium batteries Type BA 5590 U or four NiCad batteries Type BB 590 U The battery connectors are mounted in the bottom of the battery enclosure box For battery in...

Page 20: ...ll frequency bands 12 5 kHz intermediate frequency IF Bandwidth on 136 174 MHz and 12 5 kHz channel spacing on 403 470 MHz bands 12 5 kHz tuning steps Channels receive and transmit 14 channels each pr...

Page 21: ...iver Module 30 88 MHz Transceiver Module 136 174 MHz Transceiver Module 403 470 MHz SS 4100807 512 SS 4100819 502 SS 4100820 501 SS 4100821 501 SS 4100822 501 2 2 2 2 2 Cable Assembly Tactical Repeate...

Page 22: ...nical manuals Table 1 6 Related Technical Manuals Publication Number Publication Title 31R2 2PRC139 1 Operation and Maintenance Instructions with Illustrated Parts Breakdown Organizational Level for R...

Page 23: ...e g 44 feet for 30 88 MHz from power lines and other antennas etc 2 3 UNPACKING AND INSPECTIONS Exercise care when removing units from packing material in order to prevent damage to the unit Removing...

Page 24: ...d for Figure 2 1 1 Operating instructions 5 Barrier bag 2 Polystyrene top 6 Polystyrene bottom 3 Tactical repeater assembly 7 Fiberboard box 4 Desiccant bag 8 Packing slip Figure 2 1 Packaging Diagram...

Page 25: ...e the tactical repeater for any period of time before installation proceed as follows a Clean the tactical repeater before placing in storage if necessary Refer to paragraph 6 3 3 2 b Disconnect anten...

Page 26: ...plexer antenna ANT output to RF IN of power supply W5 SS 3500279 502 Strap Assembly Ground Connects tactical repeater assembly to external ground W6 SS 3500279 503 Strap Assembly Ground Connects diple...

Page 27: ...for 30 88 MHz operation with the appropriate receiver transmitters and diplexer If using a different configuration substitute the appropriate antenna receiver transmitters and diplexer Refer to Chapte...

Page 28: ...the top antenna section Connect the top coaxial cable connector to the antenna and attach cable strain relief to hole in web of adapter Rest flat edge of adapter on ground to provide convenient acces...

Page 29: ...used for a radius marker Attach the fixed upper snap hook to the attachment point on the antenna adapter Attach the running hook at the lower end to ground anchor 2 Note that the winder remains attac...

Page 30: ...a should progressively walk towards bottom of mast as it is raised and should hold mast steady as it reaches the vertical Person b attaches free guy ropes to ground anchor 1 and tightens all ropes m C...

Page 31: ...to a ground screw on the tactical repeater assembly frame next to the power supply assembly To install place the tactical repeater in its selected operating location Locate the ground lug on the fram...

Page 32: ...eater b Ensure that the mode switches on both receiver transmitters are set to CLR and the SCAN switch is turned off NOTE Other programmable parameters may be set to any value NOTE Be sure to align th...

Page 33: ...N This indicates that the unit is receiving power from the power converter 3 3 3 2 Operational Check Perform the operational checkout included in paragraph 6 2 to verify that the major components of t...

Page 34: ...ign fit all protruding parts with packing spacers wrap the complete assembly with plastic or place in a plastic air lock bag Wrap with a protective cellulose foam or similar material Wrap assemblies t...

Page 35: ...nic assembly construction the leads connectors and pins have been stiffened to make them more rugged As a result such parts are brittle and will break easily if bent too often or pulled on too hard Wh...

Page 36: ......

Page 37: ...Figure 4 1 and described in Table 4 1 4 2 2 Power Supply Switches and Connectors The tactical repeater power switches and top connectors are located on the power supply assembly The power switches are...

Page 38: ...a transmission Illuminates also in the TUNERX mode to indicate keying of the RCV receiver transmitter 4 1 4 XMT Transmit LED amber When illuminated in OP2WATT and OP10WATT modes indicates retransmiss...

Page 39: ...battery power source or an external DC source when the AC DC POWER switch is in the DC position 4 2 2 AC DC POWER DC OFF AC switch three position toggle switch Allows the operator to turn the tactica...

Page 40: ...r Connectors Function 4 3 1 AC Power Fuse 1 Amp In line fuse for AC input power 4 3 2 External Power Input Connector External power supply input 4 3 3 Antenna Out Coaxial cable to antenna 4 3 4 RF In...

Page 41: ...from diplexer transmit connector to repeater 4 4 2 POWER Connector J1 Connects repeater to repeater power supply unit 4 4 3 GND Ground Stud Provides chassis ground point connects repeater unit to fra...

Page 42: ...inputs 4 5 3 RCV Receive Control The RCV control adjusts the bandpass frequencies of the diplexer for the RCV receiver transmitter Movement of the RCV control corresponds to the RCV frequency dial mo...

Page 43: ...llow for diplexer tuning e Set the diplexer SENS control 2 Figure 4 5 fully clockwise f Release locking ring on diplexer RCV tuning dial 3 Figure 4 5 If the receive frequency is known adjust the RCV t...

Page 44: ...s received If the receive receiver transmitter is programmed for a CTCSS receive tone and the repeater receives an encrypted format the RCV LED 3 Figure 4 1 will not illuminate however the encrypted m...

Page 45: ...n a cable reel but should be pulled out in a straight line to avoid having loops in the cables When cables are not needed they should not be connected to the equipment Burying cables a foot or more wi...

Page 46: ......

Page 47: ...5 2 1 15V DC DC Converter Circuit Card Assembly CCA A1 The 15V DC DC converter CCA A1 provides regulated 15 VDC to the repeater control CCA A3 and both hand held receiver transmitters The DC DC conver...

Page 48: ...TO 31R2 2TRC199 1 5 2 Figure 5 1 Tactical Repeater System Functional Block Diagram 28 120...

Page 49: ...se part of the battery connector which mate with matching notches in the different units in which they are installed This prevents inadvertent installation of the RT 1696 U C in the tactical repeater...

Page 50: ...NIC CIRCUITS 5 3 REPEATER CONTROL CIRCUIT CARD ASSEMBLY CCA A3 See Figure 5 2 As shown in Figure 5 2 the repeater control CCA A3 consists of the following major functions a Input limiter b Clear path...

Page 51: ...TO 31R2 2TRC199 1 5 5 Figure 5 2 Repeater Control CCA A3 Functional Block Diagram...

Page 52: ...TO 31R2 2TRC199 1 5 6 Figure 5 3 15 Watt Power Amplifier Assembly A6 Functional Block Diagram...

Page 53: ...fication Check the tactical repeater power up operation as follows a Ensure that the antenna has been installed as indicated in paragraph 2 10 1 Refer to the tactical repeater interconnection diagram...

Page 54: ...eiver transmitter is illuminated and that the green LED on the XMT receiver transmitter is not illuminated 6 2 4 Transmit Tune Mode Verification Verify functionality of transmit mode as follows NOTE B...

Page 55: ...X Cleaning see paragraph 6 3 3 2 X D Daily M Monthly W Weekly Q Quarterly 6 3 2 Inspection Many potential or existing faults can be detected by making a visual inspection of the equipment For this rea...

Page 56: ...All solutions which suggest replacement of an item assume that the item used to make the replacement is a known good item Table 6 5 contains the symptoms of possible system malfunctions which can be a...

Page 57: ...Repeater receives and transmits with power and modulation Failed tactical repeater assembly Return the tactical repeater assembly to the repair specialist for repair Bad or no programming Check recei...

Page 58: ...raded sensitivity and b Repeater transmits with correct power and modulation Failed tactical repeater assembly Return the tactical repeater assembly to the repair specialist for repair Improper diplex...

Page 59: ...but not all frequencies meet specified levels Failed tactical repeater assembly Return the tactical repeater assembly to the repair specialist for repair Mismatched receiver transmitter Ensure same co...

Page 60: ...e tactical repeater assembly to the repair specialist for repair Failed RCV receiver transmitter Replace RCV receiver transmitter Failed XMT receiver transmitter Replace XMT receiver transmitter Repea...

Page 61: ...nd replace 15W RF power amplifier assembly Fault LED is illuminated Fault cannot be isolated repaired at the repair specialist level Return the tactical repeater assembly to depot for repair Repeater...

Page 62: ...r to the repair specialist for repair Table 6 7 Cross Reference to Removal Replacement Procedures Items to be Removed Replaced Applicable Procedure Paragraph Number Antenna Antenna cable Control panel...

Page 63: ...e the receive RCV or transmit XMT receiver transmitter as follows a Remove the receiver transmitter from the tactical repeater by turning the locking knob on the front panel counterclockwise one quart...

Page 64: ...performed by the operator These procedures are not applicable to the operator Prior to performing any remove replace procedures ensure the equipment is powered down and disconnected from the power so...

Page 65: ...e cover off e The 15 watt power amplifier assembly A6 1 Figure 7 2 is mounted on the top of the tactical repeater chassis 13 First unscrew the 20 captive screws 2 Figure 7 3 that hold the PA assembly...

Page 66: ......

Page 67: ...one index number assigned is sufficient The index number appears on the same line as the first part composing the group b Part Number Column This column lists the contractor s part number drawing numb...

Page 68: ...Codes This manual contains Joint Military Services Uniform SMR codes Detailed coding criteria may be obtained from T O 00 25 195 7 3 NUMERICAL INDEX The Numerical Index Chapter 7 Section III is compi...

Page 69: ...assemblies sensitive to damage by ESD T O 00 25 234 should be consulted for specific information on how damage can occur to electronic parts assemblies and equipment by ESD and the control measures to...

Page 70: ...Flex Seals Inc 23386 Racal Communications Inc 23657 Shakespeare Co 27264 Molex Inc 52437 Bretford MFG Inc 73734 Federal Screw Products Inc 74790 National Lightening Corp 76385 Minor Rubber Co Inc 7955...

Page 71: ...TO 31R2 2TRC 199 1 7 5 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN...

Page 72: ...TO 31R2 2TRC 199 1 7 6 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN...

Page 73: ...TO 31R2 2TRC 199 1 7 7 This Page Left Blank Intentionally...

Page 74: ...TO 31R2 2TRC 199 1 7 8 Figure 7 1 Radio Set AN TRC 199 Sheet 1 of 2...

Page 75: ...TO 31R2 2TRC 199 1 7 9 Figure 7 1 Radio Set AN TRC 199 Sheet 2 of 2...

Page 76: ...0001 XB 7 1 6 SS 3100546 501 23386 Clamp Rear 0001 XB 7 1 7 MS51957 79 96906 Screw Machine 23386 77682 SPEC CTRL DRW 0001 PAOZZN 7 1 8 MS35338 139 96906 Washer Lock 23386 75006 SPEC CTRL DRW 0012 PAO...

Page 77: ...WDG4 96906 Cable Clamp 23386 SS 81284 SPEC CTRL DRW 0002 PAOZZN 7 1 30 W2 SS 3500292 501 23386 Cable Assy Coaxial 0001 XB 7 1 31 W4 SS 3500292 503 23386 Cable Assy RF Coaxial 0001 XB 7 1 32 W1 SS 4500...

Page 78: ...1 41k Q86 1BZ19 Ground Spike 0002 POAZZN 7 1 41l SL33642 1 1BZ19 Transit Bag 0001 PAOZZN 7 1 42 CPRG223 U 30 XX 79557 Cable Coaxial Antenna 23386 SS 1600315 1 SPEC CTRL DRW 0001 PAOZZN 7 1 43 SS 31005...

Page 79: ...TO 31R2 2TRC 199 1 7 13 Figure 7 2 Tactical Repeater Assembly SS 4100806 501 Sheet 1 of 2...

Page 80: ...TO 31R2 2TRC 199 1 7 14 Figure 7 2 Tactical Repeater Assembly SS 4100806 501 Sheet 2 of 2...

Page 81: ...L DRW 0020 PAFZZN 7 2 7 MS51957 15 96906 Screw Machine 23386 79614 SPEC CTRL DRW 0012 PADZZN 7 2 8 MS3212 13 96906 Screw Machine 23386 79144 632 06 SPEC CTRL DRW 0016 PADZZN 7 2 9 SS 4400226 1 23386 G...

Page 82: ...ntrol ESD 0001 PADZZN 7 2 30 A9 SS 4100823 502 23386 Sleeve Assembly Short 0001 PADZZN 7 2 31 77616 23386 Screw Machine 23386 77616 SPEC CTRL DRW 0006 PADZZN 7 2 32 82 61461 53217 Plate Retaining Elec...

Page 83: ...her Flat 23386 75106 SPEC CTRL DRW 0001 PADZZN 7 2 44 F4NY 250BK 85480 Cable Clamp 23386 81252 SPEC CTRL DRW 0002 PADZZN 7 2 45 Z 2212 76385 Grommet 23386 SS 81226 SPEC CTRL DRW 0001 PADZZN 7 2 46 FSU...

Page 84: ...TO 31R2 2TRC 199 1 7 18 This Page Left Blank Intentionally...

Page 85: ...TO 31R2 2TRC 199 1 7 19 Figure 7 3 Power Amp Assembly 15W SS 4100853 501...

Page 86: ...Units per Assy Usable on Code SMR Code 7 3 SS 4100853 501 23386 Power Amplifier Assy 15W ESD 0001 PAOLDT 7 3 1 SS 4100855 501 23386 Amplifier Assy 15W refer to T O 31R2 4 1085 5 for breakdown ESD 7 3...

Page 87: ...06 7 1 14 MS15795 804 7 2 6 MS35650 104 7 1 15 71206 7 2 38 MS15795 810 7 1 9 MS35690 410 7 1 13 77616 7 2 31 MS15795 810 7 2 37 MS51957 14 7 2 35 82 61461 7 2 32 MS15795 806 7 2 25 MS51957 15 7 2 7 8...

Page 88: ...Number Figure Item Number SS 1600322 503 7 1 33 SS 4100823 502 7 2 27 Z 2212 7 2 45 SS 2400523 1 7 1 3 SS 4100836 501 7 3 3 SS 2400577 1 7 1 27 SS 4100853 501 7 2 1 SS 2400578 1 7 1 24 SS 4100853 501...

Page 89: ...dio Set AN TRC 199 7 1 REF W3 7 2 12 A1 7 1 1 W4 7 2 39 A3 7 1 33 W5 7 2 40 A3 7 1 33 W6 7 2 17 A3 7 1 33 W7 7 2 16 A4 A5 7 1 2 W9 7 2 14 W1 7 1 32 W2 7 1 30 W3 7 1 23 W4 7 1 31 W5 7 1 34 W6 7 1 12 W7...

Page 90: ...TO 31R2 2TRC199 1 7 24 Section V COMMON BULK ITEMS LIST Part Number CAGE Code Description Unit of Measure No 222 50CC 05972 Threadlocking Compound No 222 23386 91172 A R...

Page 91: ...TO 31R2 2TRC199 1 8 1 8 2 blank CHAPTER 8 0 CIRCUIT DIAGRAMS 8 1 SCOPE This chapter contains the following diagram Figure No Title FO 1 Radio Set AN TRC 199 Interconnection Diagram...

Page 92: ......

Page 93: ...TO 31R2 2TRC199 1 FP 1 FP 2 blank FO 1 Radio Set AN TRC 199 Interconnection Diagram...

Page 94: ......

Page 95: ...ect current DRW Drawing ESD Electrostatic discharge ESDS Electrostatic discharge sensitive EXT External F Fahrenheit FM Frequency modulation modulated GND Ground HF High frequency HZ Hertz IF Intermed...

Page 96: ......

Page 97: ...Controls T4 4 F4 4 Indicators Controls and Switches T4 1 F4 1 Power Switches T4 2 F4 2 Connectors T4 3 F4 3 D DC DC Converter CCA A7 Functional System Operation P5 2 6 Description Equipment Antenna As...

Page 98: ...V DC DC Converter CCA A7 P5 2 6 H Handling and Storage P3 6 Handling Material P2 6 I Installation Buildings and Other Support Structures P2 8 Cables P2 7 T2 2 Housing P2 4 Interconnection Diagram FO 1...

Page 99: ...nctional Operation of Electronic Circuits P5 4 Functional System Operation P5 2 5 Removal Replacement Procedures P6 5 2 3 Power Supply Assembly Description P1 1 2 5 Removal and Replacement Procedures...

Page 100: ...enance P6 3 3 Servicing Intervals P6 3 1 T6 4 Site Preparation P2 2 Support Equipment P1 6 T1 4 T Tactical Repeater Assembly Description P1 1 2 1 F7 2 Indicators Controls and Switches T4 1 F4 1 Remova...

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