Installation Manual

ION
Installation Manual
Rev. 1.6
Rev Description Date
Number
1.0 Original document release NOV 2015
1.1 Minor content revisions, updated installation drawings DEC 2015
1.2 Audio information, updated installation drawings, and updated text JUN 2016
description based on new installation drawings. Added change
tracking (black lines in margin)
1.3 Minor text updates SEP 2016
1.4 Updated audio pin-outs, Installation diagram supplement added DEC 2016
1.5 Added additional specifications for analog video JAN 2017
1.6 Grounding requirements updated, misc. other updates JUN 2017
Churchill Navigation Support ● Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 2

Table of Contents
About this Manual ............................................................................................................... 4
Product Guarantee & Warranty Information ........................................................................ 4
Section 1: Specifications ....................................................................................................... 5

1.0 Description ........................................................................................................................... 5
1.1 Design Characteristics .......................................................................................................... 5
Section 2: Installation Guidelines ......................................................................................... 8

2.0 Description ........................................................................................................................... 8
2.1 Equipment Packaging........................................................................................................... 8
2.2 Required Tools ..................................................................................................................... 8
2.3 Installation ........................................................................................................................... 9
Section 3: Aircraft Post-Installation Testing Procedures ...................................................... 14
Section 4: Installation Diagrams .......................................................................................... 17
Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 3

Notice:
The information contained in this document is considered confidential and proprietary to Churchill
Navigation. Neither the document nor the information contained therein should be disclosed or
reproduced in whole or in part, without express written consent of Churchill Navigation.
Changes or modifications not expressly approved by Churchill Navigation could void the user’s
authority to operate the equipment.
Non-Churchill Navigation part numbers referenced in this manual are not maintained by Churchill
Navigation and may be subject to change without notice.
All information depicted in this manual, including hardware and software names, versions, and part
numbers, is subject to change and may not be up to date.
About this Manual

This manual describes the physical, mechanical, and electrical components, as well as instructions for
the installation of the Churchill Navigation ION. Every effort has been made to make this document as
complete and accurate as possible.
The following symbols for warnings, cautions, and notes are used to throughout this manual.
! Warning A warning symbol denotes an item where a potential hazard capable of

producing injury to personnel or destruction of equipment exists if the
approved procedure is not followed.
! Caution A caution symbol denotes an item where, if not followed, damage to

equipment or degradation of mission capability can occur.
 Note The note symbol is used to identify important information for installers /
operators. While not directly related to safety or protection of equipment from
 damage, the note symbol identifies information to which attention should be
paid during the installation and/or operation of the equipment.
Product Guarantee & Warranty Information

For details about the Churchill Navigation ION warranty, please see the Terms and Conditions page
available at www.churchillnavigation.com/agreement

Specifications
Section 1: Specifications
This document contains information that was current as of the printing of this manual. To obtain
 always up-to-date installation drawings, ICDs, and much more, visit:
www.churchillnavigation.com/specifications

1.0 Description
This section contains information concerning the physical characteristics and technical specifications of
the Churchill Navigation ION video recorder.
1.1 Design Characteristics

ION is a compact, solid-state DZUS mounted video recorder. ION offers simultaneous recording of two
channels of HD-SDI video, one channel of analog video, audio, and metadata. Video is saved to
removable USB or SD media for easy transport and hand-off. A full-color, backlit LCD display allows
operators to review recorded clips on the go and even perform playback while recording.
7 2 3
1
6 5 4
8
1. Backlit, full-color, 2.15 in [54.61 mm] diagonal LCD screen
2. Backlit REC button
3. Backlit Mute button
4. Control knob (inner knob, outer knob, and push-button operation)
5. SD media (2x)
6. USB 3.0 (2x)
7. Fault light
8. CMOS Battery access tray (located on the bottom of the enclosure) *
* CMOS battery access tray included on ION hardware revision 2.8 and higher.

Specifications
1.2 Technical Characteristics & Specifications
Specification Characteristic
Product Designation/Description ION Video Recorder
Physical Dimensions Height at bezel: 1.875 in [47.63 mm]
Width at bezel: 5.75 in [146.05 mm]
Length (Enclosure depth): 7.0 in [177.8 mm]
Overall depth, front knob to back of enclosure, excluding
connectors: 8.32 in [211.33 mm]
Weight 2.6 lbs ± .05 lbs [1.18 kg ± .02 kg]
Display type / dimensions / Backlit LCD, 2.15 in [54.61 mm] diagonal
resolution Native 320 x 240 pixel resolution
NVIS Class A compliant / NVIS class B compatible
Environmental Qualifications DO-160 Qualified
Operating Temperature Range -20°C to +70°C
Maximum Operating Altitude +45,000 feet [+13,716m]
Power:
Input Voltage 28VDC
Input Current 4A on 28VDC (normal operating range)
Power consumption 112W (maximum)

Circuit Breaker Requirement Minimum 7.5 amp rated
Connection Types, Protocols, and LEMO (1x) J1 – Power/GPIO
Standards LEMO (1x) J2 – Ethernet
LEMO (1x) J3 – Misc. (USB, ARINC 429, Audio)
LEMO (1x) J4 – Serial port (RS232, RS422)
BNC J5, J6, J7 – HD-SDI 1 & HD-SDI 2 video in /

HD-SDI video out
BNC J8, J9, J10 – Analog in
Wi-Fi compatibility – 802.11ac

Video-in Support 2x HD-SDI inputs
- Single channel, 3G-SDI (1080p60) input supported
1x Analog video input (CVBS, Y/C, YPbPr, & RGB)
Video-out Support 1x HD-SDI output
- 3G-SDI (1080p60) output supported

Specifications
Video-out Supported Resolutions 720p (50 fps), 720p (60 fps), 1080p (25 fps), 1080p (30 fps)
1080p (60 fps), 1080i (50 fps), 1080i (60 fps)
Metadata Standard KLV MISB/STANAG 4609 compliant
Video Recording Codec H.265 (HEVC) – Skylake processor models only

H.264 (MPEG-4)
H.262 (MPEG-2)
Audio-in Support L/R channel in
Audio-out Support L/R channel out

Section 2: Installation Guidelines
2.0 Description
Installation
This section contains information and instructions for the unpacking and correct installation of the
Churchill Navigation ION video recorder.
2.1 Equipment Packaging

Prior to installation, carefully inspect both the ION unit and the supplied power connector. Note any
damage that may have occurred in transit and contact the parcel carrier if necessary to file a claim.
Otherwise, check that all items listed below are present prior to proceeding with the installation. Report
any missing items to your supplier.
- (1) ION
- (1) ION power connector (p/n FGN.1M.308.XLCT)
- (2) SD Cards (32GB each)
- Product manuals and guides
It is recommended that you retain all original packaging for purposes of easy returns due to
 damage or warranty claims.

All other connectors are available for purchase from Churchill Navigation or direct from the
manufacturers themselves. Additional information is provided in section 2.3 of this guide. If you have
purchased additional hardware, such as the ION Connector Kit, from Churchill Navigation, please take a
moment to inspect the condition of those connectors as well prior to starting the installation process.
2.2 Required Tools

You will need the correct crimping tool for the connectors selected. A few examples are listed below
and are available from Churchill Navigation or from their respective manufacturers.
BNC Connectors:
Application Connector: Crimp Die:
75ohm BNC plug for PICWire V73263 PicWire P/N 190712 M22520/5-41
75ohm BNC plug for RG59 Amphenol P/N 112123 .255/.213/.068
75ohm BNC plug for RG179 Amphenol P/N 112133 .178/.128/.068
All LEMO Connectors:

Crimp Tool Pin Positioner Pin Extractor
DPC.91.701.V DCE.91.070.5MVC DCF.93.070.4LT

2.3 Installation
ION is intended for DZUS mount (or similar) installations. If you are unsure of the installation location,
please contact Churchill Navigation.
Installation
To ensure adequate airflow to the unit, Churchill Navigation recommends a minimum of 100mm
 between the back of the ION and any adjacent surface.

The minimum ION installation requires 28VDC power and at least one type of supported video input.
Additionally, some operators may wish to include audio-in as a part of their basic setup. The
corresponding Installation Manual sections required for minimum operation as described above are:
1) Power – Sections 2.3.1, 2.3.2, and 2.3.3.1

2) Video – Section 2.3.3.5 (HD-SDI) and Section 2.3.3.6 (Analog)
3) Optional audio-in – Section 2.3.3.3
Support for these as well as all other inputs and features are described in detail in the following sections
of this guide.
2.3.1 Voltage Requirements

ION operates on 28-volt DC power and consumes a maximum of 112 watts (4 amps on 28VDC).
Churchill Navigation recommends using a minimum 7.5-amp circuit breaker.
2.3.2 Ground Requirements

ION IS CASE-GROUNDED THROUGH THE DZUS MOUNT. If the DZUS mount is not directly grounded
to the chassis, use a minimum of 16-gauge wire to ground the DZUS mount prior to ION operation.
EXPOSED ALUMINUM IS CHROMATED. DO NOT CHEMICALLY COAT OR COVER WITH NON-
CONDUCTIVE MATERIAL.
ALL GROUND PINS EXCEPT 28V RETURN ARE GROUND CONTINUOUS TO CASE.
! Failure to properly ground the ION unit may result in damage to the ION as well
as possibly other installed equipment.
2.3.3 Cabling requirements

To ensure a properly functioning ION, the following cabling requirements are highly recommended.
Any variation will be at the sole responsibility of the dealer or installer. Detailed installation
diagrams are provided in Section 3 of this manual.
Install each cable with an 8 inch [203 mm] service loop to allow for easy servicing of the
 ION unit.

2.3.3.1 Power (J1)
Each ION is shipped with a circular LEMO 8-pin male connector, P/N FGN.1M.308.XLCT to be

used as the power connector. If you wish to use a different power connector, the connection to
28VDC input on the ION and 28VDC GND are highly recommended to be a twisted pair. Use of
22 AWG wire size is recommended. J1 also contains provisions for GPIO1 and GPIO2 and aircraft
panel dimmer brightness control.
Installation
Pin Function Description
1 28V Connect to 28V power source
2 28V GND Ground for 28V power source
3 Panel Brightness Panel brightness can be wired to aircraft cockpit dimmer
knob and has a maximum voltage input of 30V
4 Panel Brightness GND Ground for panel brightness
5 GPIO 1 GPIO
6 GPIO 1 GND GPIO Ground
7 GPIO 2 GPIO
8 GPIO 2 GND GPIO Ground
2.3.3.2 Ethernet (J2)

Churchill Navigation recommends using either PicWire PIC E50824 or EMTEQ D100-0824-006 4-
pair Ethernet cable. Both can be purchased from Churchill Navigation or directly from their
respective manufacturers at http://www.picwire.com or http://www.emteq.com Use the
connection labeled “J2 - Ethernet”. Twisted pair is indicated by color block.
Pin Function Wire color

1 TX-/BiD1- Orange
2 TX+/BiD1+ Orange/White
3 RX-/BiD2- Green
4 RX+/BiD2+ Green/White
5 BiD4- Brown
6 BiD4+ Brown/White
7 BiD3- Blue
8 BiD3+ Blue/White
2.3.3.3 Misc. (J3) – USB, Audio, ARINC

J3 contains connection provisions for Audio in/out, ARINC and USB connectivity. Twisted pairs are
indicated by color block and noted in the “pair with” column.
Pin Function Description Pair with

1 AUDIO OUT L Audio-out, left channel --
2 AUDIO IN R HIGH Audio-in, right channel --
3 AUDIO IN L HIGH Audio-in, left channel --
4 USB 5V USB 5V --
5 USB +* USB + --
6 USB -* USB - --
7 ARINC TX1-* ARINC transmit 1- ARINC TX1+
8 ARINC RX2-* ARINC receive 2- ARINC RX2+
9 ARINC RX2+* ARINC receive 2+ ARINC RX2-
10 ARINC RX1-* ARINC receive 1- ARINC RX1+
(Table continued next page)

11 ARINC RX1+* ARINC receive 1+ ARINC RX1-
12 AUDIO OUT R Audio-out, right channel --
13 AUDIO IN R LOW --
14 AUDIO IN L LOW --
Installation
15 USB GND Ground --
16 ARINC ARINC Ground --
17 ARINC TX1+* ARINC transmit 1+ ARINC TX1-
18 AUDIO OUT GND Audio Out Ground --
19 GND Ground --
* Twisted pair required.
For USB applications using J3, Churchill Navigation recommends the following:
Option A: Carlisle 28433/02171LX-4. This cable can be purchased directly from Carlisle:
http://www.carlisleit.com
Option B: EMTEQ U090-0422-100: This cable can be purchased directly from Emteq:
http://www.emteq.com
USB performance cannot be guaranteed at cable lengths greater than 10ft (3.04m)
! without the use of an extender. Contact Churchill Navigation for additional information.
Aircraft Audio Setup Recommendations:

For best audio quality, Churchill Navigation recommends that the ION audio input be connected to
a balanced (chassis ground independent) output, with -15 dBV signal levels. It is also
recommended to connect the ION audio input to a COM port, rather than a headset output.
To connect an unbalanced audio signal, ensure that the ground signal from the audio source is
shorted to ground at the source. This ground of the audio signal should then be connected to pins
13 and 14 of J3 on the Ion.
The recommended ION audio setup has been tested on common aircraft audio control systems
including the Eagle Copters USA (Geneva Aviation) G13000 Digital Audio Router and Technisonic
A711 and A711X. If you have questions regarding the best audio setup for your installation, please
contact Churchill Navigation.
ION can be configured to record stereo audio as two separate channels; ICS as channel 1
 and RX/TX (Comm) as channel 2, for example. To do this, separate audio-in via J3 pin 2
 and pin 3.
2.3.3.4 Serial Com (J4) – RS232, RS422

J4 contains connection provisions for RS232 and RS422 serial communications. Twisted pairs are
indicated by color block and noted in the “pairing” column.
The maximum speed for cable runs of less than 25 feet [7.62m] is 256 kbit/s for
!

RS232 and 8 Mbit/s for RS422.
Pin Function Description Pair with
1 RS232C TX RS232C transmit from ION --
2 RS232C RX RS232C receive to ION --
3 RS232A TX RS232A transmit from ION --
Installation
4 RS232A CTS RS232A Clear to Send --
5 RS232B TX RS232B transmit from ION --
6 RS232B RX RS232B receive to ION --
7 RS232B RTS RS232B Request to Send --
8 RS422A RX-* RS422A receive to ION - RS422A RX+
9 RS422A TX-* RS422A transmit from ION - RS422A TX+
10 RS422A TX+* RS422A transmit from ION + RS422A TX-
11 RS422B RX+* RS422B receive to ION + RS422B RX-
12 RS422B TX+* RS422B transmit from ION + RS422B TX-
13 RS232D TX RS232D transmit from ION --
14 RS232D RX RS232D receive to ION --
15 RS232E RX RS232E receive to ION --
16 RS232E TX RS232E transmit from ION --
17 GND RS232C Ground (RS232C TX/RX) --
18 RS232A RX RS232A receive to ION --
19 RS232A RTS RS232A Request to Send --
20 GND RS232B Ground (RS232B TX/RX) --
21 RS232B CTS RS232B Clear to Send --
22 RS422A RX+* RS422A receive to ION + RS422A RX-
23 RS422B RX-* RS422B receive to ION - RS422B RX+
24 RS422B TX-* RS422B transmit from ION - RS422B TX+
25 GND RS232D Ground (RS232D TX/RX) --
26 GND RS232E Ground (RS232E TX/RX) --
27 GND Ground (Extra) --
28 GND RS232A Ground (RS232A TX/RX) --
29 GND RS422A Ground (RS422A TX/RX) --
30 GND RS422B Ground (RS422B TX/RX) --
* Twisted pair required.
2.3.3.5 BNC (J5, J6, J7) – 75 Ω HD-SDI COAX Cable

ION has two HD-SDI in connections and one HS-SDI video out connection. When used with gyro-
stabilized gimbals, HD-SDI video 1 (J5) is typically used for Video In Command, HD-SDI video 2 (J6)
is typically used for a hoist camera, etc. All BNC connectors use the center pin for the signal and
the shell as the ground.
In almost all applications, Churchill Navigation recommends use of PicWire PIC V73263 lightweight
75ohm coaxial cable, P/N 190712, available from Churchill Navigation or http://www.picwire.com
If an installation requires alternative cabling, please use the following:

Alternative A: RG59 can be used in place of PicWire PIC V73263. The proper connector is
Amphenol Connex 112123. These are available from Churchill Navigation or
http://www.digikey.com
Alternative B: If RG179 is required by other equipment (ex. MX-10 gimbal), then for EMI
Installation
purposes, DOUBLE high performance 360 degree EMC individual braid shielding must be done to
RG179 cable from end to end. The proper connector is Amphenol Connex 112133, available
from Churchill Navigation or http://www.digikey.com
2.3.3.6 BNC (J8, J9, J10) – Analog video

ION is capable of recording from composite or component video sources. PAL, NTSC, S-Video, RS-
170, and component-in are supported. The following configurations are allowed:
Composite Video In S-Video In Component Video In Component Video In

(CVBS) (YUV) (RGB)
J8 J8-Luma (Y) J8-Luma (Y) J8-Green (SYNC)
J9-Chroma (C) J9-Blue Chroma (Pb) J9-Blue
J10-Red Chroma (Pr) J10-Red
For all BNC connectors, the center conductor pin is the signal and the shell is the
! ground.
Supported Analog Video Types

ION supports input from the following analog video types:
− Composite − S-Video
− Component_YUV_480i − Component_RBG_480i
− Component_YUV_576i − Component_RBG_576i
− Component_YUV_480p − Component_RBG_480p
− Component_YUV_576p − Component_RBG_576p
2.3.3.7 All Other Cables

Other cables can be selected at the installer’s discretion to meet the needs of the installation.
! All cables MUST BE SHIELDED. This includes power cables.

Section 3: Aircraft Post-Installation Testing Procedures
3.0 Description
The following tests should be performed post-installation to confirm the correct operation of the ION
video recorder in airborne applications. Additionally, these tests will identify any interference that the
ION installation may cause with existing aircraft systems. If the installed system passes all of the
applicable EMI tests, then no further action is required. If interference is observed, then the interference
must be assessed against the appropriate standards of airworthiness for the system in question.
3.1 Methodology
Testing Procedures
Most EMI tests can be conducted on the ground unless otherwise noted. Testing recommendations for
various aircraft system tests are provided below. During all tests, it is recommended that users switch
the ION unit on and off as often as required to evaluate potential EMI in all phases of ION operation.
ADF If possible set the ADF to a nearby navigation station and monitor for interference.
Autopilot If the aircraft is equipped with an autopilot or a stability augmentation system, test
fly the aircraft and verify that operation of the ION does not have adverse effects on
these systems.
GPS The GPS should be operational and navigating with at least the minimum
compliment of satellites.
Observe the GPS for any degradation in satellite status, loss of RAIM, or warning
messages/flags.
Transponder The transponder and encoder should be monitored with ramp test equipment. Set
the output of the transponder test set to 3db above the output necessary to
achieve 90% reply.
VHF Comm The VHF comm radio should have the squelch open.
Radio
Listen for any noise or detected audio signals on the VHF comm radio(s).
Navigation Operation of the Navigation radios (VOR/LOC/GS/DME receiver(s)) should be tested

Radios using known operational facilities.
Listen for any noise or detected audio signals on the VOR/LOC/GS receiver audio;
look for any moment of flags or needles on the VOR/LOC/GS navigation display(s).

3.2 Power-on Checks
Prior to performing any other tests, the user should confirm the basic operation of the ION unit. This can
be conducted using ground power or in-air using aircraft power.
1) Power the ION on and confirm the boot sequence.
2) With either USB or SD removable media inserted, use the outer knob to select a video channel
from which you want to record and press the REC button. Ensure no faults.
3) End recording by pressing the REC button a second time.
4) Playback recorded video using:
a. The ION unit’s on-screen playback capability, or
b. The removable media by inserting it into a Windows PC or Macintosh computer and
playing back the recorded .TS file. Churchill Navigation recommends using the VLC
Player available from videolan.org for playback if you encounter any difficulty playing
Testing Procedures
files back with your normal media player.
If unable to successfully complete any of these steps, begin by rechecking wiring, connections, and if
necessary, contact Churchill Navigation Support for further troubleshooting.
3.3 EMI Test

List the power plant, fuel, and other electric instruments not already in the chart provided and note any
anomalies that occur due to operation of the ION. Assess the results.
Aircraft communications & navigation equipment tests Pass/Fail

Com 1&2
Transponder &
Encoder
ADF 1 & 2
Glideslope 1&2
VOR/LOC 1&2
DME 1&2
Compass
Directional Gyro
GPS
Digital Clock
Autopilot tests Pass/Fail

Autopilot
(Table continued next page)

Coupled Approach
Stability Augmentation
Systems
Aircraft engine systems tests Pass/Fail
Fuel Pressure
Oil Temperature
Amps
Bus Voltage
Fuel %
Testing Procedures
Ng
TOT
Torque %
Annunciators
Oil Pressure
Other systems tests (as identified by the user) Pass/Fail

Section 4: Installation Diagrams
The following pages contain the installation diagrams and specific notes for the ION that were current as of
the printing of this manual. To obtain always up-to-date installation drawings, ICDs, and much more, visit:
www.churchillnavigation.com/specifications

SYSTEM WEIGHT: 2.6 lbs [1.22 kg]
±.05 lbs [0.02 kg]
INSTALLATION NOTES:
1. ION IS CASE GROUNDED THROUGH DZUS MOUNT. IF THE DZUS
MOUNT IS NOT DIRECTLY GROUNDED TO THE CHASIS, USE A
MINIMUM OF 16-GAUGE WIRE TO GROUND THE DZUS MOUNT
PRIOR TO ION OPERATION.
2. EXPOSED ALUMINUM IS CHROMATED. DO NOT CHEMICALLY
COAT OR COVER WITH NON-CONDUCTIVE MATERIAL.
3. ALL GROUND PINS EXCEPT 28V RETURN ARE GROUND
CONTINUOUS TO CASE.
4. 28V INPUT IS REVERSE-POLARITY PROTECTED.
5. RECOMMENDED POWER WIRE SIZE: 22AWG.
6. MAXIMUM POWER DRAW IS 112 WATTS (4A ON 28VDC).
5.75
0.25 7.00
FAULT
REC MUTE
1.875
0.75
0.82
1 2
5.365 1.07
3.65
5.00
NAME DATE TITLE:

DRAWN JLH 5/18/17
CHECKED NHM 5/18/17
ION*
PROPRIETARY AND CONFIDENTIAL *Includes all Ion versions
THE INFORMATION CONTAINED IN THIS
SIZE HARDWARE REVISION: REV
A
DRAWING IS THE SOLE PROPERTY OF
ALL DIM IN INCHES [MM]
CHURCHILL NAVIGATION. ANY
4
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
WEIGHT IN LBS [KG] 2.2
CHURCHILL NAVIGATION IS
PROHIBITED. DO NOT SCALE DRAWING SHEET 1 OF 7
5 3 2 1
J8 J9 J10
J1 POWER ETHERNET
J2
ANALOG IN
J8,9,10
BNC CONNECTION:
CENTER PIN: SIGNAL
SHELL: GROUND
J3 MISC. J5:HD SDI 1 IN J6:HD SDI 2 IN J7:HD SDI OUT COM J4
J5 J6 J7
COMPOSITE VIDEO IN (CVBS): COMPONENT VIDEO IN (YUV): HD-SDI VIDEO 1 IN:

J8 J8-LUMA (Y) J5
J9-BLUE CHROMA (Pb)
J10-RED CHROMA (Pr) HD-SDI VIDEO 2 IN:
J6
S-VIDEO IN: COMPONENT VIDEO IN (RGB):
J8-LUMA (Y) J8-GREEN (SYNC) HD-SDI VIDEO OUT:
J9-CHROMA (C) J9-BLUE J7
J10-RED
For use with gyro-stabilized gimbals, HD-SDI

video 1 is typically used for Video In Command,
HD-SDI video 2 is typically used for hoist camera
NAME DATE TITLE:
DRAWN JLH 5/18/17
CHECKED NHM 5/18/17
ION*
A
4
5 3 2 1
1
J1 POWER ETHERNET
J2
2 7
8 ANALOG IN
3 6 J8,9,10
1
4 5 2 7
8
3 6
4 5
J1: Power/GPIO
1.28V
2.28V GND J3 MISC. J5:HD SDI 1 IN J6:HD SDI 2 IN J7:HD SDI OUT COM J4
3.Panel Brightness J3: J2: Ethernet
4.PB GND 1:AUDIO OUT L 1:TX-/BiD1- (Orange)
5.GPIO 1 2:AUDIO IN R HIGH 2
1 12
11
2:TX+/BiD1+ (Orange/White)
6.GPIO 1 GND 3:AUDIO IN L HIGH 3 14
13
18 10
3:Rx-/BiD2- (Green)
7.GPIO 2 4:USB 5V
19
4 15 17 9
16
4:RX+/BiD2+ (Green/White)
8.GPIO 2 GND 5:USB D+ 5
6 7
8
5:BiD4- (Brown)
Panel Brightness is to be 6:USB D- 6:BiD4+ (Brown/White)
wired to aircraft 7:ARINC TX1-* 7:BiD3+ (Blue)
cockpit dimmer knob 8:ARINC RX2-*
and has a maximum 13:AUDIO IN R LOW 8:BiD3- (Blue/White)
voltage input of 30V 9:ARINC RX2+*
10:ARINC RX1-* 14:AUDIO IN L LOW
11:ARINC RX1+* 15:USB GND
*AVAILABLE ONLY ON
12:AUDIO OUT R 16:ARINC GND ION REV A
17:ARINC TX1+*
While populating LEMO 18:AUDIO OUT GND Maximum current draw
connectors, please follow 19:GND on rear USB is 1 Amp
the pattern on the rear of
1
2 7
8
3
4 5
6
the male LEMO, as seen to
the left
TITLE:
Mating Connector DRAWN
NAME
JLH
DATE
5/18/17
(Specifically FGN.1M.308.XLCT) CHECKED NHM 5/18/17
ION*
A
4
5 3 2 1
J1 POWER ETHERNET
J2
ANALOG IN
J8,9,10
J4: SERIAL PORTS

1: RS232C TX 11: RS422B RX+* 21: RS232B CTS
2: RS232C RX 12: RS422B TX+* 22: RS422A RX+*
3: RS232A TX 13: RS232D TX 23: RS422B RX-* 2
1 16
17
15
4: RS232A CTS 14: RS232D RX 24: RS422B TX-*

3 18 26 14
4 19 27 25 13
28 30
5: RS232B TX 15: RS232E RX 25: GND (RS232D)

5 20 29 24 12
6 21 22 23 11
6: RS232B RX 16: RS232E TX 26: GND (RS232E)

7 10
8 9
7: RS232B RTS 17: GND (RS232C) 27: GND

8: RS422A RX-* 18: RS232A RX 28: GND (RS232A)
9: RS422A TX-* 19: RS232A RTS 29: GND (RS422A)
10: RS422A TX+* 20: GND (RS232B) 30: GND (RS422B)
*TWISTED PAIR REQUIRED
MAXIMUM SPEEDS FOR
CABLES LESS THAN 25FT
RS232: 256kbps NAME DATE TITLE:
RS422: 8Mbps DRAWN JLH 5/18/17
CHECKED NHM 5/18/17
ION*
A
4
5 3 2 1
Churchill has stock of all necessary connectors and tools
MATING CONNECTOR PLUGS
(CABLE TERMINATION)
All Lemo Connectors Use:
J1: FGN.1M.308.XLCT (One Provided with each Ion) Crimp tool: DPC.91.701.V
Pin Positioner: DCE.91.070.5MVC
J2: FGU.1M.308.XLCT Pin Extractor: DCF.93.070.4LT
J3: FMN.2M.319.XLCT
J4: FMN.3M.330.XLCT
J1 POWER ETHERNET
J2
ANALOG IN
J8,9,10
NAME DATE TITLE:

DRAWN JLH 5/18/17
CHECKED NHM 5/18/17
ION*
A
4
5 3 2 1
CABLING REQUIREMENTS
In order to ensure a properly working Churchill Navigation Ion System, these cabling requirements are highly recommended and any variations will be at the sole responsibility of the
installer. Please also install each cable with an 8 inch service loop for easy removal and replacement of unit.
Power Cable
The connection to 28V input on the Ion and 28V GND are highly recommended to be a twisted pair.
75ohm HD-SDI COAX CABLE

Option A
PicWire PIC V73263 is highly recommended. A 74271142S Ferrite should be placed on the cable closest to the Ion to reduce noise further. The proper connector is PicWire P/N
190712. These are available from Churchill Navigation or at http://www.picwire.com/pdfs/PIC_Connectors/PIC_190712.pdf.
RG59 is also highly recommended. A 74271112S Ferrite should be placed on the cable closest to the Ion to reduce noise further.The proper connector is Amphenol Connex 112123.
These are available from Churchill Navigation or at http://www.digikey.com/product-search/en/connectors-interconnects/coaxial-connectors-rf/1443098?k=112123
Option B
If RG179 is required by other equipment (ex. MX-10 gimbal), then for EMI purposes, DOUBLE high performance 360 degree EMC individual braid shielding must be done to RG179
cable from end to end. A 74271142S Ferrite should be placed on the cable closest to the Ion to reduce noise further. The proper connector is Amphenol Connex 112133. These are
available from Churchill Navigation or at http://www.digikey.com/product-search/en?wt.z_cid=ref_hearst_0211_buynow&site=us&mpart=112133&v=115
CRIMPING TOOL
You will need the correct crimping tool for the connectors selected. A few examples are listed below and are available through Churchill Navigation:
Connector: Crimp Die:

Picwire P/N 190712 M22520/5-41
Amphenol 112123 .255/.213/.068
Amphenol 112133 .178/.128/.068
All Lemo Connectors Crimp tool: DPC.91.701.V Pin Positioner: DCE.91.070.5MVC Pin Extractor: DCF.93.070.4LT
USB CABLE
USB performance cannot be guaranteed at cable lengths greater than 15ft without the use of an extender. Contact Churchill Navigation for further details.
Option A
Carlisle 28433/02171LX-4 http://www.carlisleit.com/product/usb-cables. This cable can be purchased directly from Carlisle
Option B
EMTEQ U090-0422-100: http://www.emteq.com/cmsdocuments/EMTEQ_U090-0422-100.pdf & http://www.emteq.com/entertainment.php This cable can be purchased directly from
Emteq.
ETHERNET CABLE
Picwire PIC E50824 is highly recommended. This can be purchased directly from PICwire at http://www.picwire.com/products/data_mates.php
EMTEQ D100-0824-006 is also highly recommended. This can be purchased directly at http://www.emteq.com/ethernet-and-databus-cables.php
ALL OTHER CABLES - MUST BE SHIELDED

All other cable can be selected by installer and all cables must be shielded, including power cables.
NAME DATE TITLE:

DRAWN JLH 5/18/17
CHECKED NHM 5/18/17
ION*
A
4
5 3 2 1
AVAILABLE FROM CHURCHILL NAVIGATION
CONN-ION
ION Connector Kit (Includes all below)
Churchill Manufacturer P/N Description
Navigation P/N
CONN-PR-308 FGN.1M.308.XLCT J1 Power/GPIO - Lemo w/ pins
CONN-ETH-308 FGU.1M.308.XLCT J2 Ethernet - Lemo w/ pins
CONN-SER-330 FMN.3M.330.XLCT J4 Serial - Lemo w/ pins
CONN-PIC PIC 190712 75Ω BNC plug - PICWire V73263
CONN-RG59 Amphenol 112123 75Ω plug - RG59
CONN-RG179 Amphenol 112133 75Ω BNC plug - RG179
CONN-SR-9N Amphenol M85049/38-11N Strain Relief Connector
CONN-FER-S 74271142S Small Snap on Ferrite
CONN-FER-L 74271112S Large Snap on Ferrite
CONN-FER-K 74271 Ferrite Key
Tools
Churchill Manufacturer P/N Description
Navigation P/N
TOOL-PIC HX4 5120-01-335-8575 Hand crimp tool for PICWire BNC
TOOL-PIC-DIE M22520/5-41 Die set for PICWire 190712 BNC (.290/.178)
TOOL-RG59 .255/.213/.068 Die Crimp tool and die for 112123 BNC
TOOL-RG179 .178/.128/.068 Die Crimp tool and die for 112133 BNC
TOOL-LEMO DPC.91.701.V Hand crimp tool for LEMO

TOOL-LEMO-PTNR DCE.91.070.5MVC Pin Positioner for LEMO Crimp
TOOL-LEMO-EXTR DCF.93.070.4LT Pin Extractor for LEMO
NAME DATE TITLE:
DRAWN JLH 5/18/17
CHECKED NHM 5/18/17
ION*
A
4
5 3 2 1

Installation Manual

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ION

Churchill Navigation Support ● Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 2

About this Manual ............................................................................................................... 4

Product Guarantee & Warranty Information ........................................................................ 4

Section 1: Specifications ....................................................................................................... 5

Section 2: Installation Guidelines ......................................................................................... 8

Section 3: Aircraft Post-Installation Testing Procedures ...................................................... 14

Section 4: Installation Diagrams .......................................................................................... 17

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 3

About this Manual

! Warning A warning symbol denotes an item where a potential hazard capable of

! Caution A caution symbol denotes an item where, if not followed, damage to

Product Guarantee & Warranty Information

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 4

1.1 Design Characteristics

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 5

Input Current 4A on 28VDC (normal operating range)

Power consumption 112W (maximum)

BNC J5, J6, J7 – HD-SDI 1 & HD-SDI 2 video in /

Wi-Fi compatibility – 802.11ac

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 6

Video Recording Codec H.265 (HEVC) – Skylake processor models only

Audio-in Support L/R channel in

Audio-out Support L/R channel out

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 7

2.1 Equipment Packaging

2.2 Required Tools

All LEMO Connectors:

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 8

1) Power – Sections 2.3.1, 2.3.2, and 2.3.3.1

2.3.1 Voltage Requirements

2.3.2 Ground Requirements

2.3.3 Cabling requirements

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 9

2.3.3.2 Ethernet (J2)

Pin Function Wire color

2.3.3.3 Misc. (J3) – USB, Audio, ARINC

Pin Function Description Pair with

(Table continued next page)

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 10

Aircraft Audio Setup Recommendations:

2.3.3.4 Serial Com (J4) – RS232, RS422

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 11

2.3.3.5 BNC (J5, J6, J7) – 75 Ω HD-SDI COAX Cable

If an installation requires alternative cabling, please use the following:

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 12

2.3.3.6 BNC (J8, J9, J10) – Analog video

Composite Video In S-Video In Component Video In Component Video In

Supported Analog Video Types

2.3.3.7 All Other Cables

! All cables MUST BE SHIELDED. This includes power cables.

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 13

Navigation Operation of the Navigation radios (VOR/LOC/GS/DME receiver(s)) should be tested

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 14

3.3 EMI Test

Aircraft communications & navigation equipment tests Pass/Fail

Autopilot tests Pass/Fail

(Table continued next page)

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 15

Other systems tests (as identified by the user) Pass/Fail

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 16

Churchill Navigation ● Support Phone: 720.744.3300 ● E-mail: support@churchillnavigation.com 17