FreeFlight 2101 I/O PLUS User manual

INSTALLATION AND CHECKOUT MANUAL
Publication Number 82882
FreeFlight 2101 I/O
Approach Plus
GPS Navigation System
FreeFlight
S Y S T E M S

INSTALLATION AND CHECKOUT MANUAL
Publication Number 82882
Revision E, May 31, 2006
FreeFlight 2101 I/O
Approach Plus
GPS Navigation System

COPYRIGHTNOTICE
© 1997 - 2006 FREEFLIGHT SYSTEMS
Reproduction of this publication or any portion thereof by any means without the
express written permission of FREEFLIGHT SYSTEMS is prohibited. For further
information contact, Manager, Technical Publications, FREEFLIGHT SYSTEMS,
3700 Interstate 35 S., Waco, Texas 76706-3756, USA. Telephone [phone]-
0000.

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LIST OF AFFECTED PAGES
Insert latest change pages and destroy superceded pages.
Page Description Page no. Date
List of Affected Pages A May 31, 2006
Table of Contents iii May 31, 2006
Section I - General Information 1-1, 1-3 - 1-6 May 31, 2006
1-8 - 1-9 May 31, 2006
Section II - Installation 2-1 & 2-6 May 31, 2006
2-29/30 May 31, 2006
Section III - Checkout 3-3 & 3-16 May 31, 2006
Appendix C - External Inputs and Outputs C-11 - C-13 & C-15 May 31, 2006
Dates of Original and Change pages are:
Revision .......... A......... February 28, 1997
Revision .......... B......... July 14, 1997
Revision .......... C ........ April 30, 1998
Revision .......... D ........ May 7, 2002 (Name change only)
Revision .......... E......... May31,2006

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Assigned To (Job Title) Location
RECORD OF REVISIONS
Rev Revision Insertion Rev Revision Insertion
By By
No. Date Date No. Date Date

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TABLE OF CONTENTS
SECTION I - General Information
1.1 INTRODUCTION ---------------------------------------------------------------------------------- 1-1
1.2 DESCRIPTION OF EQUIPMENT------------------------------------------------------------- 1-2
1.2.1 Receiver/Display Unit ----------------------------------------------------------------------------- 1-2
1.2.2 GPS Antenna ---------------------------------------------------------------------------------------- 1-3
1.3 TECHNICAL CHARACTERISTICS----------------------------------------------------------- 1-4
1.3.1 Receiver/Display Units (P/N 81440-XX) ------------------------------------------------------ 1-4
1.3.2 GPS Antenna (P/N 81194)-----------------------------------------------------------------------1-5
1.3.3 GPS Antenna (P/N 16248-11) (alternate)---------------------------------------------------- 1-6
1.4 PARTS AND EQUIPMENT --------------------------------------------------------------------- 1-7
1.4.1 FreeFlight 2101 I/O Approach Plus GPS Receiver Display Unit ----------------------- 1-7
1.4.2 Installation Kit --------------------------------------------------------------------------------------- 1-7
1.5 ACCESSORIES NOT SUPPLIED ------------------------------------------------------------ 1-8
1.5.1 Installation-------------------------------------------------------------------------------------------- 1-8
1.5.2 GPS Cable Requirements------------------------------------------------------------------------1-8
SECTION II - Installation
2.1 GENERAL ------------------------------------------------------------------------------------------ 2-1
2.2 UNPACKING AND INSPECTING EQUIPMENT ------------------------------------------ 2-1
2.2.1 Physical Inspection -------------------------------------------------------------------------------- 2-1
2.2.2 Electrical Inspection ------------------------------------------------------------------------------- 2-1
2.3 EQUIPMENT INSTALLATION ----------------------------------------------------------------- 2-1
2.3.1 Cooling Considerations --------------------------------------------------------------------------- 2-1
2.3.2 Harness and Cable Fabrication----------------------------------------------------------------- 2-1
2.3.3 GPS Antenna Installation ------------------------------------------------------------------------ 2-2
2.3.4 Receiver/Display Unit Installation -------------------------------------------------------------- 2-4
SECTION III - Checkout
3.1 GENERAL ------------------------------------------------------------------------------------------ 3-1
3.1.1 Continued Airworthiness Requirements ------------------------------------------------------3-1
3.2 SYSTEM CHECKOUT --------------------------------------------------------------------------- 3-1
3.2.1 Preliminary Test ------------------------------------------------------------------------------------ 3-1
3.2.2 Installation Setup ----------------------------------------------------------------------------------- 3-1
3.2.3 I/O Interface Check ------------------------------------------------------------------------------ 3-12
3.2.4 GPS Receiver Tests ----------------------------------------------------------------------------- 3-14
3.3 FINAL -----------------------------------------------------------------------------------------------3-16
3.3.1 Configuration Record Sheet ------------------------------------------------------------------- 3-16

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LIST OF FIGURES
2-1 FreeFlight 2101 I/O Approach Plus J1 (37 Pin) Pin-out---------------------------------- 2-6
2-2 FreeFlight 2101 I/O Approach Plus J2 (66 Pin) Pin-out---------------------------------- 2-7
2-3 GPS Antenna Cable and Connector---------------------------------------------------------- 2-9
2-4 ARINC 743 Hi Speed GPS Antenna (P/N 81194) Installation Drawing -------------2-11
2-5 GPS Antenna (P/N 16248-11) Installation Drawing (alternate) ----------------------- 2-13
2-6 FreeFlight 2101 I/O Approach Plus Installation Drawing ------------------------------- 2-15
2-7 System Inputs ------------------------------------------------------------------------------------- 2-17
2-8 System Outputs-----------------------------------------------------------------------------------2-18
2-9 OLEO Inputs--------------------------------------------------------------------------------------- 2-19
2-10 CDI/HSI Interconnection------------------------------------------------------------------------ 2-20
2-11 Typical System Interconnection -------------------------------------------------------------- 2-21
2-12 Serial Port Input Connections -----------------------------------------------------------------2-27
2-13 Serial Port Output Connections ---------------------------------------------------------------2-29
2-14 Bipolar Serial Port Interconnections --------------------------------------------------------- 2-31
LIST OF TABLES
3-1 AUX I/O Configuration --------------------------------------------------------------------------- 3-3
3-2 ARINC 419/429 Receiver Port Options (241B and earlier software versions)------ 3-5
3-3 ARINC 419/429 Receiver Port Options (241C and later software versions) -------- 3-6
3-4 User Units ------------------------------------------------------------------------------------------- 3-8
3-5 Approach Message Options -------------------------------------------------------------------- 3-9
3-6 Advisory Message Options -------------------------------------------------------------------- 3-10

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APPENDIX A - RTCA/DO-160 Environmental Qualification Forms
A.1 RECEIVER/DISPLAYUNIT--------------------------------------------------------------------- A-1
A.2 GPSANTENNA------------------------------------------------------------------------------------ A-3
APPENDIX B - Serial Interface Specification
B.1 INTRODUCTION ----------------------------------------------------------------------------------- B-1
B.2 BASICCOMMUNICATIONPROTOCOLDESCRIPTIONS ------------------------------ B-1
B.2.1 RS-422----------------------------------------------------------------------------------------------- B-1
B.2.2 RS-232----------------------------------------------------------------------------------------------- B-1
B.2.3 RS-423----------------------------------------------------------------------------------------------- B-1
B.3 CONNECTORPINASSIGNMENTS ---------------------------------------------------------- B-2
B.4 SOFTWARECONFIGURATIONOFSERIALPORTS------------------------------------ B-3
B.5 RECEIVEPORTS--------------------------------------------------------------------------------- B-3
B.5.1 Configuration--------------------------------------------------------------------------------------- B-3
B.5.2 Encoder Data Format ---------------------------------------------------------------------------- B-3
B.5.3 RMI Data Format ---------------------------------------------------------------------------------- B-4
B.5.4 Air Data Computer Format---------------------------------------------------------------------- B-5
B.6 TRANSMITPORTS------------------------------------------------------------------------------- B-7
B.6.1 Configuration--------------------------------------------------------------------------------------- B-7
B.6.2 R0 and R1 Data Formats ----------------------------------------------------------------------- B-7
B.6.3 K0 and K1 Data Formats -----------------------------------------------------------------------B-10
B.6.4 X0 and X1 Formats ------------------------------------------------------------------------------B-13
B.6.5 Data Output Format Example -----------------------------------------------------------------B-17
APPENDIX C - External Inputs and Outputs
C.1 EXTERNAL INPUTS ----------------------------------------------------------------------------- C-1
C.1.1 Speed Inputs --------------------------------------------------------------------------------------- C-1
C.1.2 Heading Input -------------------------------------------------------------------------------------- C-3
C.1.3 Discrete Inputs ------------------------------------------------------------------------------------- C-3
C.1.4 Digital Data Inputs--------------------------------------------------------------------------------- C-4
C.2 SYSTEM OUTPUTS ----------------------------------------------------------------------------- C-5
C.2.1 Lateral Deviation (DC Crosstrack) (LT/RT) ------------------------------------------------- C-5
C.2.2 Nav Flag --------------------------------------------------------------------------------------------- C-5
C.2.3 TO/FROM ------------------------------------------------------------------------------------------- C-5
C.2.4 Steering ---------------------------------------------------------------------------------------------- C-6
C.2.5 Glideslope (UP/DN)------------------------------------------------------------------------------- C-6
C.2.6 Glideslope Flag ------------------------------------------------------------------------------------ C-6
C.2.7 Discretes--------------------------------------------------------------------------------------------- C-8
C.2.8 HSI #1, 2, and 3 Synchros ---------------------------------------------------------------------- C-9
C.2.9 Digital Data Bus-----------------------------------------------------------------------------------C-10
APPENDIX D - STCs and Flight Manual Supplements
APPENDIX E - Local Geodetic Reference Datums

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FreeFlight 2101 I/O Approach Plus GPS Navigation System
SECTION I
GENERAL INFORMATION

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TABLE OF CONTENTS
SECTION I - General Information
1.1 INTRODUCTION ---------------------------------------------------------------------------------- 1-1
1.2 DESCRIPTION OF EQUIPMENT------------------------------------------------------------- 1-2
1.2.1 Receiver/Display Unit ----------------------------------------------------------------------------- 1-2
1.2.2 GPS Antenna ---------------------------------------------------------------------------------------- 1-3
1.3 TECHNICAL CHARACTERISTICS----------------------------------------------------------- 1-4
1.3.1 Receiver/Display Units (P/N 81440-XX) ------------------------------------------------------ 1-4
1.3.2 GPS Antenna (P/N 81194)-----------------------------------------------------------------------1-5
1.3.3 GPS Antenna (P/N 16248-11) (alternate)---------------------------------------------------- 1-6
1.4 PARTS AND EQUIPMENT --------------------------------------------------------------------- 1-7
1.4.1 FreeFlight 2101 I/O Approach GPS Receiver Display Unit------------------------------ 1-7
1.4.2 Installation Kit --------------------------------------------------------------------------------------- 1-7
1.5 ACCESSORIES NOT SUPPLIED ------------------------------------------------------------ 1-8
1.5.1 Installation-------------------------------------------------------------------------------------------- 1-8
1.5.2 GPS Cable Requirements------------------------------------------------------------------------1-8

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SECTION I - General Information
1.1 INTRODUCTION
This manual provides information about the electrical, mechanical, and physical characteristics of the FreeFlight 2101 I/O
ApproachPlusGPSReceiverDisplayUnitP/N 81440-XX. Thefirstsectionservesasanintroduction. Itdescribesthetechnical
specifications of the Dzus-mounted Receiver/Display unit, and the externally mounted GPS antenna. The following sections
describe the installation and checkout procedures. Proper techniques must be followed to ensure correct operation.
1.2 DESCRIPTION OF EQUIPMENT
TheFreeFlight2101I/OApproachPlus Receiverprovideslong-rangeGPSnavigationviaaDzus-mounted unit. Eachsystem
comprises receivers and antennas to perform specified functions. The Jeppesen database cards provide up-to-date
information about airports and other navigation aids around the world. The FreeFlight 2101 I/O Approach Plus GPS System
comprises one Dzus-mounted Receiver/Display Unit (RDU) containing a GPS Receiver (12-channel), one GPS Antenna/
Preamp, and applicable installation hardware (see Section 1.4.2 for the appropriate part numbers). The Jeppesen database
cards are available separately. The part numbers are P/N 81461-10 for North American information, P/N 81461-12 for
Eurasian information, and P/N 81461-13 for Pacific/South American information. The first card is supplied by FreeFlight.
CAUTION
Use of the GPS antenna for IFR installations in aircraft equipped with satellite communication equipment should be
tested to ensure no interference exists between the SATCOM equipment and the GPS antenna.

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FreeFlight 2101 I/O Approach Plus GPS Navigation System
1.2.1 Receiver/DisplayUnit
The Receiver/Display Unit (RDU) is the main component of the FreeFlight 2101 I/O Approach Plus navigation
system. The RDU consists of the GPS Receiver, the User Interface, and the System Interface.
1.2.1.1 GPS Receiver
The GPS Receiver interprets the satellite transmissions to determine the current position. This information is
communicated to the pilot via the User Interface and to the connected equipment via the System Interface.
1.2.1.2 User Interface
The User Interface is accomplished by an LED Display, five annunciator lights, nine push-button keys, two
concentric selector knobs, a power switch, and a NavData card slot.
A. LED Display
TheLightEmittingDiode(LED)Displayisa two-line,high intensitydisplay with20charactersperline.
System information is shown on the display.
B. Annunciator Lights
The internal annunciator lights alert the pilot of warning and advisory messages. The annunciator
lightsaretheMessage(MSG),Hold(HLD),ParallelTrack(PTK),Approach(APR),andWaypointAlert
(WPT).
C. Push-Button Keys
Ninepush-buttonkeysareusedformodeselectionanddataentry. Thekeysaredescribedasfollows:
Access Navigation Mode. Displays enroute navigation information.
AccessWaypointMode. Allowspilottovieworselectairports,SIDs,STARs,Approaches,
VORs, NDBs, Intersections, and User-defined locations as waypoints in a flight plan or
as a destination. Also allows pilot to create, edit, or delete User-defined waypoints.
Access Flight Plan Mode. Allows pilot to create, use, edit, reverse, and delete flight
plans.
Access Calculator Mode. Allows pilot to perform many common E6B computer
calculations.
Access Auxiliary Mode. Provides information about system status, sensor status,
system setup and installation procedures. Also contains a programmable checklist
function.
Shows twenty nearest airports, VORs, NDBs, intersections, user-defined waypoints,
approaches, and agencies.
Allows pilot to fly direct to the indicated location or activate the indicated flight plan.
Enters information into memory and used to begin and end data entry.
Allows the pilot to view system messages.

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D. Selector Knobs
Two concentric selector knobs are used to select displays within modes and for data entry.
E. Power Switch
A knob power switch turns the RDU on and off.
F. NavData Card Slot
The NavData card slot accepts the Jeppesen NavData card which provides the pilot information on
Airports, SIDs, STARs, Approaches, VORs, NDBs, and Intersections.
1.2.1.3 System Interface
The FreeFlight 2101 I/O Approach Plus communicates with connected equipment by the CDI outputs,
Annunciators, the Serial Inputs/Outputs, and the Digital Inputs/Outputs.
A. CDI Outputs
The RDU provides standard Course Deviation Indicator (CDI) output signals suitable for use by most
CDIs.
B. Annunciator Outputs
The external annunciator lights alert the pilot of warning and advisory messages. The annunciator
lights are Message (MSG), Hold (HLD), Waypoint Alert (WPT) and Approach (APR).
C. Serial Inputs/Outputs
The RDU provides two serial input ports and two serial output ports for general use. Data formats are
software selectable.
D. Digital Inputs/Outputs
The RDU provides four two-wire digital input ports, three two-wire digital output ports and one six-wire
digital output port. Data formats are all software selectable.
1.2.2 GPS Antenna
The GPS Antenna (P/N 81194) receives and amplifies GPS Signals. The GPS Antenna unit is an omnidirectional
flat microstrip antenna with an integral preamplifier and is rated to 1300 knots IAS. An alternate antenna
(P/N 16248-11)canbeusedwiththeFreeFlight2101I/OAPPROACHPlusininstallationswithoutSatcom. Antenna
P/N 81194 is recommended.

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1.3 TECHNICAL CHARACTERISTICS
1.3.1 Receiver/DisplayUnits(P/N81440-XX)
ENVIRONMENTAL COMPLIANCE See Appendix A
TSO COMPLIANCE C129 (A1)
PHYSICAL DIMENSIONS
Height 3.0 in (7.62 cm)
Width 5.70 in (14.48 cm)
Depth 7.68 in (19.50 cm)
WEIGHT 3.25 lbs (1.48 kg)
TEMPERATURE
Navigation Unit -20° to +70° C
Database Card 0° to +55° C
ALTITUDE -1000 ft to +50,000 ft
MAXIMUM TRACK VELOCITY 800 knots*
MOUNTING Dzus Rail
POWER REQUIREMENTS 1.5 A @ 28 Vdc
* Complies with USA export requirements
ExternalInterfaces:
TYPE I/O NO. PARAMETER
Synchro Input 4 TAS
HDG
Altitude (2)
Voltage Ratio Input 1 TAS
ARINC 429 Input 4 High or Low Speed
Discrete Input 9 Various, including Spares
Synchro Output 3 Programmable Synchro/Resolver Output
Autopilot Output 1 Roll Sum Steering
Analog Deviation Output 3 Cross Track
Glideslope
Autopilot Left/Right
Digital ARINC Output 3 419/429 (2)
561/568 (1)
Discrete Output Output 15 Various, including Spares
Serial Input/Output 3 Differential GPS
Air Data Computer
Test and Maintenance
Altitude Encoder
Data Logging

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1.3.1.1 GPS Receiver
TYPE L1 Frequency (1575 MHz), C/A Code,
Twelve Channel
ACQUISITION TIME 1.5 to 3.5 minutes
POSITION UPDATE RATE 5 per second
DYNAMICS 800 knots, 6g (tracking)
ACCURACY
Position 15 meters RMS**
Velocity 0.1 knots steady state**
Altitude 35 meters RMS** (MSL)
Time UTC to the nearest microsecond
** Selective Availability not implemented
1.3.2 GPS Antenna (P/N 81194)
TSO COMPLIANCE C129, C144 *
ENVIRONMENTAL COMPLIANCE See Appendix A
PHYSICAL DIMENSIONS
Height 0.60 in (1.52 cm)
Width 3.00 in (7.62 cm)
Length 4.70 in (11.94 cm)
WEIGHT 0.375 lb (0.17 kg)
TEMPERATURE -55°C to +85°C
ALTITUDE RANGE -100 ft to +55,000 ft
MOUNTING External
POWER REQUIREMENTS +5 Vdc @ 40 mA max from RDU
SPEED RATING 1300 knots IAS
CONNECTOR TNC
* Use of the GPS antenna for IFR installations in aircraft equipped with satellite communication equipment
should be tested to ensure no interference exists between the SATCOM equipment and the GPS antenna.

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1.3.3 GPSAntenna(P/N16248-11)(alternate)
TSO COMPLIANCE C115a, C129 *
ENVIRONMENTAL COMPLIANCE See Appendix A
PHYSICAL DIMENSIONS
Height 0.80 in (2.0 cm)
Width 3.75 in (9.53 cm)
Length 4.00 in (10.16 cm)
WEIGHT 0.5 lb (0.23 kg)
TEMPERATURE -55°C to +70°C
ALTITUDE RANGE -1000 ft to +55,000 ft
MOUNTING External
POWER REQUIREMENTS +5 Vdc @ 80 mA from RDU
SPEED RATING 800 knots IAS
CONNECTOR TNC
* Installations utilizing this antenna are limited to aircraft not equipped with Satellite Communications equipment.