Flightcell CRP 05001 User manual

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Flightcell Iridium Extreme Cradle
Installation and Operation Manual
MAN_CR5_001
Document version 1.0
Date 05 November 2014
www.flightcell.com

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Contents
1Introduction 4
2Specifications 5
3Installing your Flightcell Iridium Extreme Cradle 6
3.1 Mounting the phone cradle within your aircraft or vehicle.................................................................................. 6
3.2 Wiring the cradle...................................................................................................................................................................... 6
3.3 The main connector ................................................................................................................................................................ 6
3.4 Audio connection ..................................................................................................................................................................... 7
3.5 Antenna connection ................................................................................................................................................................ 7
3.6 Data connection ........................................................................................................................................................................ 8
3.7 Power supply to the Iridium phone................................................................................................................................. 8
4Using the Iridium phone with the Flightcell Iridium Extreme Cradle 9
4.1 Installing and releasing your Iridium satellite phone ............................................................................................. 9
4.2 Automated power on and off .............................................................................................................................................. 9
5Warranty and contact details 10
5.1 Limited warranty for your Flightcell Iridium Extreme cradle.......................................................................... 10
5.2 Flightcell International contact details ....................................................................................................................... 10
6Version history 11

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1Introduction
The Flightcell Iridium Extreme Cradle is used to install an Iridium Extreme satellite phone in an aircraft or
vehicle. The phone cradle provides secure mounting for the Iridium handset and interfaces all necessary
antenna, power, voice and data connections.
The cradle also contains noise suppression technology to reduce intrusion of aircraft power supply noise into
the audio system.
The cradle has been designed for use with the Flightcell DZMx voice, data and tracking system. The DZMx
integrates the Extreme phone into the aircraft communications system.
The cradle may also be used to connect an Iridium Extreme phone direct to an aircraft audio panel.
This manual is intended for use by engineers installing and maintaining the Flightcell Iridium Extreme Cradle.
It describes the physical, mechanical and electrical characteristics and installation requirements for the
product.
For further information or support, contact your Flightcell reseller or contact Flightcell International Ltd
direct.
Contact details are provided at the end of this document.

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2Specifications
Part number
CRP_05001
Material
Machined from aluminium 6061-T6
Powder coated finish
Input voltage
12-32V DC (28V Nominal)
Power supply current
Operating current 250mA max (@28V)
Phone charge voltage
5.0V
Microphone bias voltage
5.0V via 2.2kΩ
Mic audio
Input Levels
20mVrms to 1.15Vrms, adjustable
775mVRMS nominal
Input impedance
600Ω
SPKR audio
Output levels
Up to 3Vrms into 150Ω, adjustable
775mVRMS nominal
Output impedance
150Ω
Satphone data
RS-232 levels, 9600bps
Dimensions
Width
Overall
70mm
2.76”
Depth with or without phone
65mm
2.58”
Height: including satphone
236mm
9.30”
excluding satphone
222mm
8.74”
Weight
Including satphone
956g
33.7oz
Excluding satphone
680g
24.0oz
Main connector on cradle
DB25 male (8FTM25P-30N1-FEC)
Antenna connector
TNC

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3Installing your Flightcell Iridium Extreme Cradle
3.1 Mounting the phone cradle in your aircraft or vehicle
Dimensions and mounting points are provided in drawing DRW_CR5_010_9575CradleMechanicalAssembly_1.0,
included on the USB drive supplied with your cradle or available from the support pages the Flightcell
website. ( www.flightcell.com/support.aspx )
Use 4 x M5 bolts at the four mounting points on the back of the cradle. These bolts are fastened into the back
of the cradle through a bulkhead or other similar mounting point.
The length of the bolts should be the thickness of the mounting surface plus a maximum of10mm.
3.2 Wiring the cradle
The following guidelines should be followed when constructing wiring looms:
Power cables should be 22AWG stranded. For example, M22759/34-22-9
Other cables may be 22 or 24AWG stranded, screened where indicated. For example, M27500/-
24SB2T14
Screened pairs should be used for:
MIC +/-
SPK +/-
RS232 Tx/Rx
The other flow control lines RTS, CTS, DSR, DTR, RI, DCD can utilise either screened or unscreened
cables in any groupings. Where screened cable is used, we recommend that it be grounded at one end
only to minimize ground loops
Where the GPO signal is used we recommend using a single screened cable, with GPO GND connected
to the screen and GPO connected to the core.
3.3 The main connector
The D25 main connector contains all required I/O connections to charge the satellite phone and access the
serial port and audio connection.
Cradle main connector (D25 male) part number - TE Connectivity 1-1634582-2 (or equivalent)
Mating connector (D25 female) part number - M24308/2-3F (or equivalent).
Pin
Function
Input to/output from
phone cradle
Notes
1
Do not connect
2
Do not connect
3
Do not connect
4
Do not connect
5
RI
Output
6
Power -
Input
7
GND
Signal GND
8
Data RX
Input
9
DTR
Input
Flow control
10
RTS
Input
Flow control
11
GND GPO
Output
12
MIC +
Input
13
SPK +
Output
14
Do not connect

7
15
Do not connect
16
DCD
Output
RS232 flow control
17
Do not connect
18
DSR
Output
RS232 flow control
19
PWR +
Input
20
GND DATA
21
SAT TX
Output
22
CTS
Output
23
GPO
General Purpose Output for
custom applications
24
MIC
Input
25
SPK -
Output
Shell
Chassis ground
3.4 Audio connection
Audio is passed between phone cradle and phone using the digital audio connection in the base of the phone.
The headset audio jack on the side of the phone is NOT used.
3.4.1 Connection to the audio panel using a Flightcell DZMx
If the cradle is used to connect an Iridium Extreme handset to a Flightcell DZMx, refer to the installation
manual and interconnect drawings for the DZMx.
These documents are supplied with the DZMx or can be downloaded from the Flightcell support page at
http://www.flightcell.com/support.aspx.
3.4.2 Direct connection to the audio panel without using a Flightcell DZMx
The cradle can be interfaced directly to an audio panel, provided that audio levels are compatible.
If connected to an audio panel, the cradle always provides mic bias and sidetone.
3.5 Antenna connection
The Flightcell Iridium Extreme Cradle has a single TNC antenna connector to connect the phone to an
approved Iridium antenna. Please contact Flightcell International or your Flightcell supplier for information
on antenna options.
Iridium antenna cables must be selected to keep signal loss within accepted levels. Total signal loss on the
Iridium connection between the cradle and the antenna should not exceed 3dB at 1626MHz.
The maximum length recommended for different common antenna cable types is:
Cable Length
Cable Specification
Notes
Up to 4m
RG58C/U
Up to 6m
LMR200/U-9006 cellfoil
Up to 8m
RG213
It is recommended that the
antenna cable be reduced to RG58
for the last 300mm next to the
cradle to assist with installation.
Up to 15m
LMR400
Up to 23m
LMR600

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3.6 Data connection
The main connector on the phone cradle is wired for an RS232 serial data connection. The serial data
connection is configured for 9600 baud.
3.7 Power supply to the Iridium phone
The Iridium phone cradle contains a power supply that manages the voltage supplied to the phone to levels
required to safely charge and operate the phone. Power is supplied via the connector on the base of the
Iridium phone.

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4Using the Iridium phone with the Flightcell Iridium Extreme
Cradle
4.1 Installing and releasing your Iridium satellite phone
The Iridium Extreme has a hinged rubber bung on its base, covering the data connector.
Unplug the bung and swing around so it clips in behind the two retaining lugs on the back of the phone
Next, to mount the phone in the cradle:
1. Locate the base of the phone on the
locating pins on the cradle data connector
2. Depress the latch on the top of the cradle
3. While pressing the phone down against
the locating pins, rotate it backwards
until it is hard against the back of the
cradle (note that it is necessary to press
the phone downwards against the
resistance of the rubber cushioning
around the phone)
4. Release the latch.
To release the phone, depress the latch and rotate
the phone out of the cradle.
4.2 Automated power on and off
The Iridium phone cradle is designed to power the Iridium phone on and off when the aircraft or vehicle is
powered up or down. This is done to ensure the phone is always on when the aircraft is operating, and the
phone is always off (and batteries are not being run down) when no power is being supplied from the aircraft.
Retaining lug
1
2
3
Retaining
pins

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5Warranty and contact details
5.1 Limited warranty for your Flightcell Iridium Extreme cradle
Flightcell International Ltd's quality products are proudly designed and manufactured to the highest
standards in New Zealand.
Your Flightcell Iridium Extreme Cradle is warranted for 2 years from date of sale.
The warranty is void if any labels are removed or if it is determined that your Flightcell DZM has been:
Connected to a power supply delivering more than 32 Volts;
Connected with reverse polarity;
Installed in direct contravention to the guidelines outlined in the technical installation manual;
Physically damaged, or a fault has occurred due to the product being used beyond what is considered
normal use, causing unusual deterioration of the product.
If the product is deemed to be faulty or in need of repair, please contact Flightcell International Ltd to obtain a
Returned Materials Authorization.
5.2 Flightcell International contact details
Flightcell International Ltd
PO Box 1481
98 Vickerman Street
Nelson 7040
New Zealand
Telephone [phone]
Fax [phone]
Email [e-mail]
Website http://www.flightcell.com

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6Version history
Release version
Date
Author
Change note
number
Description
Issue 1
5 November 2014
J Mace
FCN0646
Document created.