FEC HP0722 User manual

FEC Mobile Lighting Controller Version 2 (MLC V2)
Type: FEC - HP0722
User Manual –Specification –Diagnostics
Figure 1
MLC
Issue: 1.00 6th September 2017
Powered by eAGLe Light Engines
® Interleader Limited

© Interleader Limited 2017 2 of 30 Printed: 06/09/2017
Document Revision Sheet
Issue
Date
Changes
1.00
06/09/2017
New Document for MLC V2 –Telit UHF module
Figure 2
MLC and MIL-Star®
The eAGLe logo and MIL-Star®name are copyright of Interleader Limited 2017

© Interleader Limited 2017 3 of 30 Printed: 06/09/2017
Contents
1Compliance Statements - USA....................................................................4
2Compliance Statement - Europe..................................................................5
3Overview.....................................................................................................6
4Architecture.................................................................................................6
5Capabilities..................................................................................................7
6System........................................................................................................8
7Basic Operation...........................................................................................9
8Normal Operation......................................................................................10
9Default Settings.........................................................................................11
10 Battery Run-time.......................................................................................12
11 Sunset/Sunrise Switching..........................................................................13
12 Battery Capacity ‘Traffic Light’ LED indicators ...........................................14
13 Charging ...................................................................................................15
14 MLC Dimensions.......................................................................................17
15 MLC and Carry/Charger Case Weight.......................................................17
16 Environmental (MLC) ................................................................................17
17 Electrical Specification (MLC)....................................................................18
18 UHF Radio Modem Specification...............................................................19
19 Special Orders ..........................................................................................20
20 Spare Parts...............................................................................................20
21 Support Documentation.............................................................................20
22 The Carrying and Charging Case..............................................................21
23 UHF Antenna ............................................................................................22
24 VHF Antenna and Cables..........................................................................23
25 Diagnostics and Fault Finding ...................................................................25
26 Transportation...........................................................................................26
27 Packaging and Labelling ...........................................................................26
28 Software Updater - MLC............................................................................27
29 Wireless Command Mode.........................................................................28
30 Wired Interface..........................................................................................29

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1 Compliance Statements - USA
FCC Compliance WARNING
Changes or modifications to the transmitter not expressly approved by the manufacturer could void the
user's authority to operate this RF device.
FCC Compliance Statement
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
1. This device may not cause interference, and
2. This device must accept any interference, including interference that may cause undesired operation
of the device.
USA-Federal Communications Commission (FCC)
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment generates, uses, and can radiate radio
frequency energy. If not installed and used in accordance with the instructions, it may cause harmful
interference to radio communications. However, there is no ensured specification that interference will
not occur in a particular installation. If this equipment does cause harmful interference to radio or
television reception, which can be determined by tuning the equipment off and on, the user is
encouraged to try and correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the distance between the equipment and the receiver.
• Connect the equipment to outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Any changes or modifications not expressly approved by the party responsible for compliance could
void the user’s authority to operate the equipment.

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2 Compliance Statement - Europe
This product has been marked with the CE mark to show it is compliant with the relevant standards.

© Interleader Limited 2017 6 of 30 Printed: 06/09/2017
3 Overview
The Mobile Lighting Controller (MLC) offers VHF control of helipad lights and peripheral equipment
either via a UHF transceiver link (to MIL-Star®lights) or using internal relay drivers.
The unit is housed in the same enclosure as the FEC MIL-Star®range of battery helipad lights.
Part Numbers
HP0722 - Standard VHF version
4 Architecture
The MLC is an integral member of the FEC family of lights and controllers enabling either MIL-Star®
battery portable lights, Remote Switching Controllers or fixed installation lights to be activated by pilots
or ground staff by VHF radio.
The MLC is configured (e.g. setting VHF frequency), managed and may be controlled via a UHF
wireless link from a PC or Laptop (not supplied) running FEC’s Systems Management Software.
The MLC is designed to be carried and charged in a MIL-Star®case providing a complete, portable
solution in a single case. Charging power can be mains, car, truck or solar.
Figure 3

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5 Capabilities
FEC’s Mobile Lighting Controller Version 1 (MLC V1) is an all new, fully digital design that combines
ease of installation and use with sophisticated yet simple and secure configuration via a wireless PC
Controller Software interface.
The MLC incorporates an advanced microcontroller to provide very flexible and programmable
operation, combining proven designs from the FEC Remote Lighting Controller (RLC) and MIL-Star®
battery helipad lights.
Key Features
Traditional VHF Pilot Lighting Controller (PLC) configuration
Modern, digital, fully synthesised VHF receiver with programmable:
o25kHz/8.33kHz frequency setting
o‘Click’ period (range: 50 – 250mS, Default 100mS)
oSignal strength threshold (range: -10 to -100dBm, Default: -75dBm)
Defined number of presses to activate Channels 1, 2 or 3
oVHF wireless
oLocal magnetic key
oPC Controller
Each channel has fully independent programmable time-out (10 seconds to 60 minutes)
3 Channels + 1 Auxiliary transistor switch output to control external power relays
Built in light sensor for optional automatic switching at sunrise and sunset
Built in real-time clock calendar
Stealth mode - provides the facility to turn off the status LEDs after an initial confirmation period
(5 seconds).
Housed in MIL-Star®enclosure
oCan be carried in standard Carry/Charger case
oReplaces one of the 8 MIL-Stars
oCompatible charging points for simple lead-free charging
oWhip antenna stored in case lid
Internal 7.5V 2.2Ah Li-Ion battery giving many days operation
Remote test and diagnostics integrated into the unit
Very low power consumption –Approx. 0.5W
Operates from internal battery or 12V DC (ideal for solar and batteries)

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6 System
The key system elements of the MLC are shown in figure 4 (top removed for clarity).
The three connectors at the top of the unit are IP65 rated and fitted with dust caps (cap colour may
vary).
6.1 Charging & Relay Interface Connector
This 8way Lockable DIN SWUM
1
connector can be connected to an external power supply (12.5 –30V
DC) to power/charge the unit and provides 4 transistor switch outputs (3 channels + 1 auxiliary) to
switch external power relays.
6.2 VHF and UHF Antenna Connectors
The VHF and UHF antenna connectors are SMA sockets (reverse gender for USA). The supplied whip
antenna is fitted with an SMA plug for direct connection. For fixed installations customers can choose
the most appropriate antenna and cable (See later section on antenna).
1
SWUM –Sealed When Un-Mated
Int. UHF
Antenna
Wireless
LEDs
Serial
Number
USB Port
Channel &
Aux LEDs
Battery
State LEDs
VHF Rx
Power &
CD LEDs
Battery
Isolator
(under)
‘Click’
sensor
‘Off’ sensor
‘On’ sensor
Status LED
Charger & Relay
Connector
VHF Connector
Charging Power
Studs (bottom face)
Charging
LEDs
UHF
Connector
Figure 4

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7 Basic Operation
Basic On, Off and Channel selection of the MLC is achieved by activating magnetic sensors inside the
unit using a Magnetic Key Controller (MKC) (supplied).
7.1 Turn MLC On
To turn an MLC on, momentarily bring the MKC
in line with the ‘On’ sensor on the unit’s top
panel (figure 5).
If the unit is already on, holding the MKC to the
On sensor for 2 seconds puts the unit in
Communication Mode (see later section)
7.2 Turn MLC Off
To turn an MLC off, momentarily bring the MKC
in line with the ‘Off’ sensor on the unit’s top
panel (figure 6).
If the unit is already off, bringing the MKC in line
with the ‘Off’ sensor, displays the battery status
(useful for a quick check without having to turn
the unit on)
The Off sensor is also used to put the MLC into
software update mode (see later section)
7.3 Select MLC Channel
Channels may be selected without a VHF radio.
With the unit switched on, momentarily bring the
MKC in line with the ‘Click’ sensor on the unit’s
top panel (figure 7) 3, 5 or 7 times within a 5
second period (just as the pilot would do via
VHF).
As each ‘click’ is detected the ‘Status’ LED will
light and, after the 5 second period, the selected
channel will be activated. (See later section for
defaults)
Figure 5
Figure 6
Figure 7

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8 Normal Operation
As soon as a VHF signal is detected on frequency the Carrier Detect (CD) LED on the VHF Receiver
and the blue Status LED will light for the period that the signal is detected.
During a 5 second period (the international standard for Pilot Controlled Lighting) the system is
counting ‘clicks’ from the pilot. The number of clicks (CD) received in the 5 second period is counted
and at the end of that period the following occurs:
Clicks
Action
Comment
1, 2, 4, 6 or 8
or more clicks
No action taken
Return to standby
One click will be detected any time a pilot or ground station
on frequency presses their Push-To-Talk (PTT) microphone
button.
3
Activate channel 1
If Auxiliary output has been assigned to the selected
channel it will also be turned on.
The assigned Group and Program command is transmitted
by UHF to activate MIL-Star lights.
After the time-out period the lights are turned off again.
5
Activate channel 2
7
Activate channel 3
If no action is taken then the system will return to standby ready to receive new input.
At any time the pilot can re-activate the same channel or activate a different channel by pressing their
PTT again the required number of clicks. The channels requested will be activated and the time-out
period will begin counting down again.
The default settings are shown in the next section.

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9 Default Settings
The default MLC settings are as below:
9.1 Clicks to Channel Mapping
The following shows the channels that will be selected following the receipt of the correct number of
‘clicks’ in a 5 second period:
Clicks
Channel
Program
Auxiliary
Timeout
Minutes:Seconds
Comment
Default
Options
Default
Options
Default
Option
Default
Range
1, 2,
4, 6
None
None
None
None
None
None
None
None
Input
ignored
3
1
0, 1, 2, 3
1
1 to 5
Off
On, Off
15:00
10S-1M
(10S
steps)
1-60M
(1M steps
Channel 0
is useful for
‘disabling’ a
number of
clicks
5
2
0, 1, 2, 3
1
1 to 5
Off
On, Off
15:00
7
3
0, 1, 2, 3
1
1 to 5
Off
On, Off
15:00
9.2 VHF Radio Settings
The VHF radio is set as follows:
Parameter
Default
Range
Comment
Frequency
122.800
118.00 to 136.98
Configuration uses 8.33kHz channel display convention
Threshold
-75dBm
-10 to -100dBm
Take care using values lower than -85dBm
‘Click’ Period
100mS
(1/10second)
50mS to 250mS
9.3 UHF Radio Settings
UHF radio settings are restricted to Original Equipment Manufacturer (OEM) set-up.
9.4 General Settings
Other settings are as below:
Parameter
Default
Range
Comment
Sunset/Normal Switching
Normal
Sunset/Normal
Not implemented this software version
Sunset Light Level
400 Lux
200 –800 Lux
PC Controller Software will force a 100 Lux
minimum gap to avoid the unit ‘hunting’
Sunrise Light Level
500 Lux
Sunset + 100
Stealth/Normal Mode
Normal
Stealth/Normal
Running Flash Period
1,000mS
TBC
Not implemented this software version
Flash Period
100mS
TBC
9.5 System Settings
System settings are restricted to OEM set-up.

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10 Battery Run-time
10.1 System Off
When ‘Off’, the MLC is in low power ‘sleep’ mode waiting for activation via the magnetic switches. In
this condition most of the systems are shut down to conserve power but the microcontroller and
sensors are still drawing a small current.
This constant small drain will reduce the battery to half charge in approximately 18 months.
It is essential that the batteries are checked and charged at least every 12 months (see later sections).
10.2 Normal Operation
When the MLC is turned On the systems are fully operating, the VHF receiver is powered on but, to
ensure maximum battery run-time the UHF transceiver is off until it is required to switch MIL-Star®
lights on or off.
The UHF transceiver will then be switched on for the period of the command and then be powered off
again.
In this mode the fully charged run-time is 3 days.
If deployed continuously it is essential that the batteries are checked and charged at least every 2 days
(see later sections).
10.3 Communication Mode
To configure the MLC via the PC Controller Software requires that the UHF tranceiver is powered on.
To do this, with the unit switched on, hold the magnet to the On sensor for two seconds until the blue
Status LED comes on. The MLC is now in Communication Mode and will respond to requests from the
PC Controller Software.
To ensure maximum battery life the system will automatically drop out of Communication Mode ten
minutes after the last legitimate request from the PC Controller Software. When this happens the blue
Status LED goes out and the PC Controller Software will no longer be able to communicate with the
MLC.
Important Notes
1) The run-time figures above have been obtained from a new unit with a fully charged battery.
2) Battery performance will degrade slowly over time and with charge cycles.
3) This is a guide only and should be validated by the operator prior to use.
4) There will be a variation of run times between MLCs.
5) The MLC will run until the battery is exhausted and then suddenly turn off.

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11 Sunset/Sunrise Switching
The MLC can be set to automatically switch the lights on at sunset and off again at sunrise in exactly
the same way as individual MIL-Star®lights - except that all lights will be turned on or off together.
When switched to this mode in daylight, the Battery Capacity LEDs will light as normal and MIL-Star®
lights will be set off. When the light level becomes less than 400 Lux (the level of light at sunset on a
clear day) the defined channel will be turned on. Note that it is the light level that turns the lights on and
off, not the time of day. Very overcast conditions causing a dark sky may cause light levels to drop
significantly below 400 Lux even though the time is not at sunset. This will cause the MLC to switch
lights on (see test results below).
The MLC monitors light level continuously and if the ‘sunrise’ light level of 500 Lux is exceeded, the
lights will be turned off again. This may lead to a situation where if the MLC is set to automatic and
before sunset a large black cloud causes the lights to be turned on, but then moves away, they may go
back off again (as happened in the test below).
The graph below shows the drop in light level from 60 minutes before sunset to sunset. The green bars
indicate the actual time the test set of lights came on. MLC results would be similar.
Meteorological conditions at time of test:
Metar from nearby Stansted Airport (EGSS) at 17:20 Zulu, 20th February 2016:
Overcast clouds at 1400 feet (recent rain and drizzle). Temp. 11C, Dewpoint 9C, RH 87% 1006hPa.
MIL-Star®- Sunset Switching Test

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12 Battery Capacity ‘Traffic Light’ LED indicators
All the time that the unit is switched on the on-board microprocessor monitors the
battery voltage to ensure that operation remains within the safe working limits of the
battery and to ensure its maximum life.
In all modes, except ‘stealth mode’, when the unit is turned on the battery
voltage/capacity is indicated via the three ‘traffic light’ LEDs (Figure 8).
Their status may be interpreted as follows:
LED Status
Battery Voltage
Meaning
Red flash every 10s
<6.00V
Battery exhausted –Switch off & Recharge
Flashing Red every 1s
6.00V - 6.25V
Battery nearing exhaustion. Switch off & Recharge
Solid Red
6.25V –6.80V
Battery low (<20% remaining).
Solid Orange
6.80V –7.50V
Battery OK (between 20% and 80% capacity)
Solid Green
>7.50V
Battery Full (>80% capacity)
In practice the green LED will not remain lit for much of the total running time. Most of the running time
is spent with the orange LED on. This is normal and to be expected.
Also note that at the transition point between, for example, orange and red, the LEDs may display
alternate orange/red at a rate of 1 second per colour. This is normal.
If the MLC has been run continuously until the battery is nearly exhausted and then turned off, the
battery voltage may ‘recover’ a little. If turned back on this may show as either the red or orange light
coming on briefly but the unit quickly indicating a low battery and shutting down.
Stealth Mode
When the unit is first switched on in Stealth Mode, the Battery Capacity LEDs will light for 5 seconds to
indicate the battery capacity. After this initial period, the Battery Capacity LEDs will turn off.
Figure 8

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13 Charging
Do NOT Charge from mains with the Case Lid Shut
The MLC is charged in a MIL-Star®carrying case using the integrated mains Power Supply Unit (PSU)
or connection to a nominal 12V or 24V DC supply (e.g. car or truck) or directly from a 12V (nominal) PV
Solar Panel.
Note that the MLC can be charged in any position but MUST be stored in the position shown as the lid
foam is relieved to accommodate the connectors.
Figure 9
Connections:
First ensure that the mains PSU and 12-24V supplies are disconnected.
Ensure that all of the lights and MLC is fitted into the case properly (clear top facing left as
Figure 9) with the Power Studs down
Either: Connect the PSU to the mains and switch on, or
Connect DC connector to a 12V –24V DC source
Charging Limits:
The mains PSU is capable of charging 8 lights (or 7 lights + 1 MLC) from exhausted to fully charged in
about 3.5 hours (max 4) if the case of the PSU is below 40C (104F). If the case temperature is above
this, only 4 lights (3 lights + 1 MLC) can be charged simultaneously.
If the case/PSU temperature is above 50oC (1220F) the PSU must not be used.

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If charging 8 lights (or 7 lights + 1 MLC) fully exhausted units from a vehicle’s 12V supply the total load
will be 4 Amps. The cable and connector (with 5 Amp fuse fitted) are capable of supporting this load.
Be aware that many vehicle supply sockets may be unable to support this load or that the vehicle’s
socket (and then the cable connector) may get hot. This could present a fire hazard. This is particularly
likely with an old, used socket. If in doubt, reduce the number of lights being charged simultaneously.
Also be aware that this load will reduce the charge available from the vehicle battery.
Battery Status LEDs:
When power is first applied to the MLC, the internal charging
circuit first determines the state of the battery, only going to full
charge if the battery passes the initial test. If there is a problem
with the battery the red Fault LED will be lit. See later section on
action to take.
The charger is an intelligent dual-rate charger and, after the
initial battery check, will determine exactly how long to charge the battery and at what rate. It will
switch off automatically at the end of the main charge. During the initial high charge rate the
Charging LED will be lit. This will extinguish once the battery is fully charged.
After Charging:
Once fully charged (and with the charger still connected and switched on) all LEDs will be off.
At this point turn off the charger.
Li-Ion batteries have a very low self-discharge current and neither need nor benefit from trickle
charging.
A refresh cycle should be performed once every 6 month (more frequently in very hot conditions
–see table below) to maintain full charge and best battery condition and life.
Temperature
Remaining Capacity
After
23oC / 73oF
95%
6 months
45oC / 113oF
80%
3 months
60oC / 140oF
80%
1 month
Disconnection:
To disconnect the charger, switch off the mains supply and remove the power cord or disconnect
the DC power cable
Re-store the cable
Good Practice:
Never charge batteries from the mains power supply with the case lid shut
There is no need to leave the charger connected
Always isolate from the mains before connecting/disconnecting
Only charge batteries indoors in dry conditions
Keep batteries away from sources of heat and direct sunlight
Routinely recycle as outlined above
Never charge a battery that appears damaged
Never use a power cord that is damaged in any way
If in doubt –have it checked out
Figure 10

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14 MLC Dimensions
MLC
Dimension
Value (mm/inches)
Comment
Width
84mm / 3.31 inches
Length
98mm / 3.90 inches
Including Power Studs and connectors fitted with
dust caps
Height
65mm / 2.56 inches
Including 6mm base –Standard product
15 MLC and Carry/Charger Case Weight
The weight of the MLC and complete sets (7 MIL-Star®+ 1 MLC, case, charger and mains and DC
cables) are as follows:
Item
Weight
(kilograms)
Weight
(US pounds)
Comment
Single Mobile Lighting Controller (6mm
Stainless Steel base)
0.73kg
1.61lb
6mm Standard base
Case –Empty (including power supply
and mains and DC cables)
4.76kg
10.49lb
System: 7 MIL-Star®+ 1 MLC in Case
(including power supply and mains and
DC cables)
10.60kg
23.37lb
Operational system
weight
System packed for Shipping
TBC
TBC
As above but with outer
foam and shipping box
16 Environmental (MLC)
Degree of protection IP65
MLC Operating temperature: -25oC to +40oC
Charging temperature: -25oC to +40oC
System Storage temperature: -25oC to +50oC
Shock –TBC
Fully ROHC Compliant

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17 Electrical Specification (MLC)
Parameter
Value
Operating voltage (nominal):
7.5V DC
Absolute voltage range:
6.0V –8.4V DC
Charger input voltage range:
12.5V –28.0V DC
Running power consumption:
0.5 watts (maximum with UHF tranceiver on)
Sleep power consumption:
0.001 watts (All radios off)
On-board fuses:
2 * 1 Amp (self re-setting type)
Reverse voltage protection:
Polarity protected on charger
Surge protection:
600W transient voltage suppressor on external charging connector
VHF antenna connector:
SMA Female socket (with dust cap)
UHF antenna connector:
SMA Female socket (with dust cap) –NB Reverse gender for USA
Charger & Relay Interface Connector
SWUM 8way Locking DIN socket
Battery:
Li Ion Battery Pack
Battery Manufacturer:
Enix
Battery Type:
MGL2807
Nominal Voltage:
7.5V
Nominal Capacity:
2.6Ah
Nominal Energy:
19.5Wh
Battery Protection:
Internal self-resetting fuse
Electrical Specification (Carry/Charger Case)
See MIL-Star Manual.

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18 UHF Radio Modem Specification
The same Telit UHF Radio Modem is used in MIL-Star, HEMS-Star, RLC, MLC, PLC and KFC and the
FEC Systems Management PC Dongle. The Modem has the following specification.
Parameter
Value
UK/EU/ROW 868 MHz
USA 915MHz
Manufacturer:
Telit
Telit
Modem type:
LE70 - 868
LE70 - 915
Nominal frequency band:
868MHz
915MHz
Frequency (sub)band:
869.525MHz (869.4 - 869.65MHz)
902 –928MHz (915.375 1st Channel)
Frequency hops/dwell time:
N/A
50/350mS
Freq. tolerance @ 20C
+/-2.5kHz
+/-2.5kHz
Rx filterb
81kHz
81kHz
Deviation:
+/-20kHz
+/-20kHz
Power output set
100mW (20dBm)
100mW (20dBm)
Receiver sensitivity:
Max –110dBm at 38.4kbps
Max –110.5dBm at 38.4kbps
Controller range:
To 200m subject to antenna & terrain
To 200m subject to antenna & terrain
Addressing - module level:
Transparent (secure addressing later)
Transparent (secure addressing later)
Addressing schema:
One to Many
One to Many
Addressing –device level:
Handled in software
Handled in software
Encryption:
None (AES 128bit later)
None (AES 128bit later)
RF Baud rate:
38.4kbps
38.4kbps
Modem data rate:
19.2kbps
19.2kbps
Modulation:
2GFSK
2GFSK
Operating temperature:
-40C to +85C
-40C to +85C
Compliance:
CE (0682)
Compliance for FCC is to 47 CFR part
15.249. FCC ID: R17LE70FH
RF Channel Selection
The EU standard sets maximum power transmission limits dependent on frequency, bandwidth
and application. A rough guidance applicable to the ZULU channel numbers is given below
Channel Number
Frequency Centre (MHz)
EU Power Allowance
mW/dBm
Notes
0
868.400
25/14
Applicable standard -
EN300-220
1
868.900
25/14
2
869.450
100/20
3
869.600
100/20
4
869.800
25/14
All specifications are manufacturer’s data

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19 Special Orders
Military Frequency Radios
At additional cost and with a Minimum Order Quantity, units can be supplied with alternative main
radios.
Please contact your FEC sales representative to discuss your particular requirements.
Software Features
At additional cost, units can be programmed to perform non-standard functions.
Please contact your FEC sales representative to discuss your particular requirements.
20 Spare Parts
There are no other user serviceable parts.
Items requiring repair need to be returned to FEC
21 Support Documentation
Documentation, including this manual, is contained on the USB
memory stick in the case (colour of USB stick will vary).
Also on the USB memory stick are short video clips that
demonstrate various aspects of setting up and using the MLC and
charger. Updates may also be posted on the FEC website.
Material on the USB Stick:
There are a number of folders on the USB Memory Stick containing:
Application Files
Systems Management Software
Battery Data
Manufacturers declaration about the battery
Labels
Battery shipping labels
Manuals
MLC manual (this document)
FEC SMS Manual
MLC Software
Software running the MLC
FEC SMS v3.0
Systems Management Software V3
Setup
Setup file for Systems Management Software
Figure 11