Codan MT-3 Instruction Manual

Technical Note for Tuning, Testing,

Maintaining and Servicing

MT-3 FM Analog Radio Systems

with the IFR COM-120 (B or C) by Aeroﬂex

TN910

Codan MT-3 and

IFR COM-120 by Aeroﬂex

Test Procedures

Codan Radio Communications

43 Erie Street

Victoria, British Columbia

Canada V8V 1P8

International

Phone: 250-382-8268

Fax: 250-382-6139

Email: [email protected]

Web: www.codanradio.com

Toll Free Canada and U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

Table of Contents

General Set-Up and Connections............................................................................. Page 3

System Regulator Testing

System Voltage Testing.................................................................................................. Page 4

Receiver Testing

Set-Up............................................................................................................................ Page 5

Distortion ........................................................................................................................ Page 6

Sensitivity (12 dB SINAD)............................................................................................... Page 6

Squelch........................................................................................................................... Page 6

Receiver andAuxiliary (AC-3E) OutputAudio Levels..................................................... Page 7

CTCSS Decode.............................................................................................................. Page 8

Receiver Front EndAlignment and Tuning..................................................................... Page 9

Transmitter Testing

Set-Up............................................................................................................................ Page 10

Distortion ........................................................................................................................ Page 12

RF Power........................................................................................................................ Page 12

Frequency Stability......................................................................................................... Page 12

Transmitter Deviation Levels.......................................................................................... Page 12

Auxiliary (AC-3E) InputAudio Levels.............................................................................. Page 13

CTCSS Encode.............................................................................................................. Page 13

Duplex Testing

Set-Up............................................................................................................................ Page 14

Distortion ........................................................................................................................ Page 15

Repeater Deviation Levels ............................................................................................. Page 15

Important Information

This Technical Note is intended as an aid to conﬁguring and testing Codan radios using an IFR COM-120 (B or C)

Service Monitor by Aeroﬂex. Neither Codan Limited or Aeroﬂex Inc. assume responsibility for damage caused to

either unit as a result of misinterpretation or misuse of this procedure. Codan manufactured Products are warranted

against defective materials and workmanship. This warranty does not extend to damage due to misuse, neglect,

accident, improper conﬁguration or installation. Codan and Aeroﬂex shall be released from all obligations under

its respective warranty in the event the Products are subject to misuse, neglect, alteration, accident, improper

installation or testing, or if un-authorized repairs are performed by the Customer or others. These procedures can

be modiﬁed, changed and altered at any time to better suit your speciﬁc needs and requirements.

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Rev 5-0-0 May 14

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

Page 3 of 16

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

General Set-Up and Connections

Frequencies and Bandwidths:

The receiver and transmitter modules are individually programmed with RF frequencies and are also designed for

wideband or narrowband operation. Familiarize yourself with all of the transmitter and receiver settings before

testing or tuning the Codan radio system.

Typical Speciﬁcations:

This document refers to some TYPICAL receiver and transmitter speciﬁcations. Refer to the Instruction Manuals

for complete radio system speciﬁcations.

Adapters, Cables and Extender Cards:

Various adapters, cables and extender cards are required for the different radio tests. Extender cards and adapters

are available from Codan Radio Communications. The receiver front end ﬁlter tuning requires an SMB - BNC

adapter (5192-WJ01BJ01) that is available from Codan Radio Communications.

Control Cards:

Most Codan MT-3 radio systems have an AC-3E or AC-3L-96 Audio Control Card for use in the radio system. The

Control Cards connect to the receiver and transmitter balanced audio lines with an unbalanced load, which could

cause some measurements to be in error. If the radio system includes an Audio Control Card, remove the control

card from the rack for the individual receiver and transmitter tests unless otherwise noted.

Audio Connections:

The Receiver, Transmitter andAuxiliary Balanced audio lines are available for connection on Codan extender cards

or by connecting to the optional back panel A-PNL-AUX96-3 screw-type terminal connector. The extender cards

have solder points available on each signal line that can have a small test point, (5059-TP110300) that is supplied

with the extender card, soldered to them for easy connection with clip-on type clips. Recommended Test Points are:

Audio Control Card Extender Card pins (EC-96D1 and EC-96K-1.22):

Auxiliary 1 Audio Output = B11 & A11

Auxiliary 2 Audio Output = C1 & C3

Auxiliary 1 Audio Input = C19 & C20

Auxiliary 2 Audio Input = B14 & A14

Receiver and Transmitter Extender Card pins (EC-48RD and EC-48RK-1.22):

Rx Balanced Audio Output = B26 & Z26

Tx Balanced Audio Input = B18 & Z18

Tx Subtone Input = B22 & Ground (B32)

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

System Regulator Testing

System Voltage Testing

The ﬁrst stage of testing a Codan MT-4E radio system is to perform a basic system check on the supply and

regulated voltages. The System Regulator module is designed with a convenient and easy test point built in to the

front panel. This test point allows a technician access to the DC supply and regulated voltages. Simply connect

a standard Digital Volt Meter (DVM) to the METER jacks on the front panel of the System Regulator as shown in

Figure 1.

Figure 1: System Regulator Voltage Testing

The FUNCTION rotary switch on the front panel of the System Regulator will allow you to test various points in the

radio system. Following is a list of System Regulator rotary switch positions, the functions they measure and the

parameters measured:

1 Supply Voltage +10 Vdc to +17 Vdc (+13.8 Vdc nominal)

2 +9.5 Volts Regulated +9.5 Vdc (± 0.1 Vdc)

3 Rx AAudio Receiver AAudio (NOT Rx Balanced Output)

4 Rx A Carrier Strength 0 Vdc to +5.0 Vdc based on received signal strength

(0 Vdc is a low RF signal level, +5.0 Vdc is high)

5 Rx B Audio Receiver B Audio (NOT Rx Balanced Output)

6 Rx B Carrier Strength 0 Vdc to +5.0 Vdc based on received signal strength

(0 Vdc is a low RF signal level, +5.0 Vdc is high)

The standby current draw of the radio system should be measured for battery / solar powered systems. Connect

an ammeter to the power input line and measure the standby current draw and transmit current draw of the system.

The maximum standby and transmit current draw is dependant on the radio system (number and class of receivers,

transmitter output power, ampliﬁers, auxiliary equipment, etc.).

Backwards Compatibility

The SM-3 System Regulator is a direct replacement for the SM-3 System Monitor, however, the rotary switch

positions for the front panel test points have been changed.

SQ . DI SA B L E

RMO

RF NI

REFERENCE

INPUT

RECEIVER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

REFERENCE

INPUT

OFF

KEY TX

MIC

RF OUT

FREQUENCY (MHz)

NORM

TRANSMITTER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

AUDIO

CONTROL

RX A

RX B

TX A

TX B

TX A

TX B

PULL DOWN

TO REMOVE

VOL

SYSTEM REGULATOR

METER

MADE IN CANADA

OFF

SPKR

INT

EXT

SPKR

OFF

POWER

FUNCTION

MIN MAXHOLD REL

Hz RANGE

ac+dc

OFF

AmA COM V

TEMPERATURE

MIN MAXHOLD REL

Hz RANGE

ac+dc

OFF

AmA COM V

TEMPERATURE

AutoHOLD LOGGING

SAVECANCEL

FAST MN MX

SETUP

YES

DIGITAL MULTIMETER

CLEAR MEM

VIEW

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Rev 5-0-0 May 14

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

Page 5 of 16

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

Receiver Testing

Connect the IFR COM-120 and Codan radio as shown in Figure 2:

Figure 2: Receiver Testing

Select the GEN MODE button and set up the IFR COM-120 as shown in Figure 3:

Figure 3: IFR COM-120 Receiver Test Conﬁguration

The AF LEVEL and SCOPE may not read as shown; these levels are set with an external 600 ohm matching load.

Audio levels will read higher without the matching load. See the Receiver andAuxiliary OutputAudio Level section

for more information. Enter the correct RF frequency, and ensure that the deviation level is set at ± 60% maximum

deviation (±3.0 KHz wide / ±1.5 KHz narrow).

On the Codan Radio system, ensure the receiver is turned on and turn the System Regulator Speaker switch ON.

Ensure the rotary select switch is set to the correct Receiver Audio (depending on the receiver being tested), then

turn the volume up until the 1 KHz tone is audible.

Rx Balanced Audio Output

(from pins B26 and Z26)

T/R port from IFR COM-120

to RF IN on Rx

AUDIO / DATA

SINAD IN

Note: The Audio Control Card should

be removed for all but the Auxiliary

Audio and CTCSS decode tests.

STORE RCL

SHOW

LIST SETUP

MEMORY

INSTRUMENTS

ANLYZSCOPE

MTRS AUDIO

GEN

MODE

RECGEN

SPCL

DPLX

DATAENTRY

132

456

789

*0#

+/-

SHIFT

ENTER

ESC

HOLD

SCRN

START

STOP

TAB

DATASCROLL

ANTENNA

10 W MAX

50 W

PHONES

SQUELCH

VOLUME

T / R

RF IN/OUT

AUX

RF OUT

AUDIO/DATA

GEN OUT

DEMOD

OUT

MIC / ACCEXT MOD

AUDIO/DATA

SINAD IN

SCOPE/DVM

POWER

SQ. DI SA B L E

RMO

RF NI

REFERENCE

INPUT

RECEIVER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

REFERENCE

INPUT

OFF

KEY TX

MIC

RF OUT

FREQUENCY(MHz)

NORM

TRANSMITTER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

AUDIO

CONTROL

RX A

RX B

TX A

TX B

TX A

TX B

PULLDOWN

TOREMOVE

VOL

SYSTEM REGULATOR

METER

MADE IN CANADA

OFF

SPKR

INT

EXT

SPKR

OFF

POWER

FUNCTION

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

Distortion:

Receiver audio distortion is typically less than 3.0 %.

Sensitivity (12 dB SINAD):

HighlightDISTORTIONandselectSINAD. HighlightLEVELandpushenteronthekeypad,thenslowlyturntheDATA

SCROLL spinner down to lower RF generator levels while monitoring the SINAD meter. The receiver sensitivity

point is where the RF generator level is for a 12 dB SINAD reading (The SINAD meter tends to jump around, look

for the closest RF level for an average of 12 dB SINAD). Receiver sensitivity is typically -116 dBm to -118 dBm

depending on the receiver model.

The IFR COM-120 setup as shown in Figure 4 shows a receiver with -119.0 dBm senstivity:

Figure 4: IFR COM-120 Sensitivity Test Conﬁguration

If the Distortion or SINAD measurements are not within Codan published speciﬁcations, the Front End may need

re-alignment. Refer to the Receiver Front End Alignment and Tuning section.

Squelch:

To check the receiver squelch points, adjust the RF carrier level up and down with the DATA SCROLL spinner until

the receiver squelches and unsquelches. There should be approximately 6 dBm of hysteresis (centered around the

sensitivity point) on MT-3 receivers. The squelch and unsquelch point can be adjusted on the receiver mainboard

(R88 & R115). Refer to the Instruction Manual or Technical Note for squelch setting procedures.

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Rev 5-0-0 May 14

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

Page 7 of 16

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

Receiver and Auxiliary (AC-3E) Output Audio Levels:

The audio level adjustment can be done on both the Rx Balanced Audio Output and the Auxiliary Balanced Output

(1 and 2). The Auxiliary Balanced Output is only available on the AC-3E Control Card. The Receiver and Auxiliary

Balanced Audio Outputs are 600 ohm balanced audio outputs and will require an external 600 ohm matching load

before an accurate measurement of the audio level can be performed by the IFR COM-120.

Rx Balanced Output:

1. Ensure the receiver is turned on and the Audio Control Card is NOT plugged into the subrack.

2. Adjust the Rx Balanced Audio level adjustment (R64 the High Level Drive Adjust) for -8.0 dBm audio level (308

mVrms @ 600 ohms). If no external 600 ohm load is available, the audio level could be adjusted for approximately

585 mVrms in the IFR COM-120.

Auxiliary Balanced Output (1 & 2):

1. Ensure the receiver is turned on and the Audio Control Card IS plugged into the subrack.

2. Connect the Auxiliary Balanced Audio Output (1 or 2) from theAC-3E to theAUDIO/DATA SINAD IN input on the

IFR COM-120.

3. Adjust the Auxiliary Balanced Audio level adjustment (R13 for Aux Out 1, R56 for Aux Out 2) for 0.0 dBm audio

level (775 mVrms @ 600 ohms). If no external 600 ohm load is available, the audio level could be adjusted for

approximately 2.50 Vrms in the IFR COM-120.

To select between dBm and Vrms, highlight AF LEVEL and select ZOOM as shown in Figure 5 . Highlight the

measurement units and select Vrms or dBm (ensure that the impedance is set to 600 Ohms when selecting dBm)

as shown in Figure 6. Hit RETURN to return to the GENERATE window.

> >

Figure 5: IFR COM-120 Audio Level Conﬁguration Figure 6: IFR COM-120 Impedance Selection

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

CTCSS Decode:

To check the CTCSS decode of the receiver, plug the Audio Control Card into the subrack and ensure that the

CTCSS decode switch is turned ON (if applicable). When the decoder is turned ON, the receiver will mute and

audio will no longer be audible at the System Regulator speaker.

If the Auxiliary Balanced Output test was the last test performed, re-connect the Receiver Balanced Audio Output

to the AUDIO/DATA SINAD IN input on the IFR COM-120. Ensure the 1.0 KHz audio tone is still injected into the

receiver (with GEN1) and that the deviation level is set at ± 60% maximum deviation (±3.0 KHz wide / ±1.5 KHz

narrow).

To inject the CTCSS tone into the receiver, highlight Mod Src and select GEN2, then highlight OFF and select FM as

shown in Figure 7. Highlight Freq and enter the CTCSS decode tone, then highlight Deviation and enter a deviation

of ±0.50 KHz wide / ±0.35 KHz narrow.

Figure 7: IFR COM-120 CTCSS Test Conﬁguration

The receiver will now un-mute and the 1 KHz tone (and possibly the CTCSS tone) will be audible on the System

Regulator speaker. If the receiver does not un-mute, check that the correct CTCSS tone frequency is entered in

the IFR COM-120.

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Rev 5-0-0 May 14

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

Page 9 of 16

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

Receiver Front End Alignment and Tuning:

Tuning of the Front End ﬁlter is typically only required when the Sensitivity or Distortion does not meet published

speciﬁcations, or when the receiver RF frequency is changed beyond the band pass of the ﬁlter (typically 5 - 7

MHz).

Connect the IFR COM-120 and Codan radio as as shown in Figure 8:

Figure 8: Receiver Front End Alignment and Tuning

The internal cable in the receiver from the output of the front end terminates in an SMB connector. The SMB plugs

directly into the Receiver 21.4 MHz IF /Audio Main Board. Disconnect the SMB cable from the Mainboard connector

and use the SMB-BNC adapter to connect this point to the ANT input on the IFR COM-120.

Select the ANLYZ INSTRUMENTS button and set up the IFR COM-120 as shown in Figure 9:

Figure 9: IFR COM-120 Spectrum Analyzer Conﬁguration

Enter the correct RF frequency and ensure the receiver is turned on. The ﬁlter waveform will appear on the scope

display. To tune the Front End ﬁlter, remove the dust caps on the variable capacitors and, starting from the capacitor

closest to the front panel and moving back, tune the ﬁlter to its new frequency.

Front End output from Receiver

to ANTENNA input on IFR COM-120

AUX RF OUT port from IFR COM-120

to RF IN on Rx

STORE RCL

SHOW

LIST SETUP

MEMORY

INSTRUMENTS

ANLYZSCOPE

MTRS AUDIO

GEN

MODE

RECGEN

SPCL

DPLX

DATAENTRY

132

456

789

*0#

+/-

SHIFT

ENTER

ESC

HOLD

SCRN

START

STOP

TAB

DATASCROLL

ANTENNA

10 W MAX

50 W

PHONES

SQUELCH

VOLUME

T / R

RF IN/OUT

AUX

RF OUT

AUDIO/DATA

GEN OUT

DEMOD

OUT

MIC / ACCEXT MOD

AUDIO/DATA

SINAD IN

SCOPE/DVM

POWER

SQ. DI SA B L E

RMO

RF NI

REFERENCE

INPUT

RECEIVER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

REFERENCE

INPUT

OFF

KEY TX

MIC

RF OUT

FREQUENCY(MHz)

NORM

TRANSMITTER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

AUDIO

CONTROL

RX A

RX B

TX A

TX B

TX A

TX B

PULLDOWN

TOREMOVE

VOL

SYSTEM REGULATOR

METER

MADE IN CANADA

OFF

SPKR

INT

EXT

SPKR

OFF

POWER

FUNCTION

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

TN910 Codan MT-3 and IFR COM-120 Test Procedures

MT-3 Radio Systems

TECHNICAL NOTES

43 Erie Street

Victoria, B.C.

Canada V8V 1P8

Toll Free Canada & U.S.A.

Phone: 1-800-664-4066

Fax: 1-877-750-0004

International

Phone: 250-382-8268

Fax: 250-382-6139

Internet

Email: [email protected]

Web: www.codanradio.com

Transmitter Testing

Connect the IFR COM-120 and Codan radio as shown in Figure 10:

Figure 10: Transmitter Testing

Select the REC MODE button and set up the IFR COM-120 as shown in Figure 11:

Figure 11: IFR COM-120 Transmitter Test Conﬁguration

Enter the correct RF frequency, and ensure that the transmitter is set to KEY TX and theAudio Control Card is NOT

plugged into the subrack. Set the receive audio ﬁlters and AF Generator frequency and level as shown in Figures

12 through 15.

MINMAXHOLD REL

Hz RANGE

ac+dc

OFF

AmA COM V

TEMPERATURE

MINMAXHOLD REL

Hz RANGE

ac+dc

OFF

AmA COM V

TEMPERATURE

AutoHOLD LOGGING

SAVECANCEL

FASTMN MX

SETUP

YES

DIGITAL MULTIMETER

CLEARMEM

VIEW

Tx Balanced Audio Input

(to pins B18 and Z18)

T/R port from IFR COM-120 to RF OUT on Tx

AUDIO/DATA

GEN OUT

Note: The Audio Control Card should

be removed for all but the Auxiliary

Audio and CTCSS encode tests.

*Tx Subtone Input 1

Deviation Level Test

(to pins B22 and Ground (B32))

Optional

External DVM

Connected to

Tx Balanced

Audio Input

STORE RCL

SHOW

LIST SETUP

MEMORY

INSTRUMENTS

ANLYZSCOPE

MTRS AUDIO

GEN

MODE

RECGEN

SPCL

DPLX

DATAENTRY

132

456

789

*0#

+/-

SHIFT

ENTER

ESC

HOLD

SCRN

START

STOP

TAB

DATASCROLL

ANTENNA

10 W MAX

50 W

PHONES

SQUELCH

VOLUME

T / R

RF IN/OUT

AUX

RF OUT

AUDIO/DATA

GEN OUT

DEMOD

OUT

MIC / ACCEXT MOD

AUDIO/DATA

SINAD IN

SCOPE/DVM

POWER

SQ. DI SA B L E

RMO

RF NI

REFERENCE

INPUT

RECEIVER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

REFERENCE

INPUT

OFF

KEY TX

MIC

RF OUT

FREQUENCY(MHz)

NORM

TRANSMITTER

FREQUENCY (MHz)

MADE IN CANADA

MODEL # CODE

AUDIO

CONTROL

RX A

RX B

TX A

TX B

TX A

TX B

PULLDOWN

TOREMOVE

VOL

SYSTEM REGULATOR

METER

MADE IN CANADA

OFF

SPKR

INT

EXT

SPKR

OFF

POWER

FUNCTION

ThisproducthasbeendiscontinuedandisnolongermanufacturedbyCodanRadioCommunications

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