FreeFlight ADS-B FDL-978 Series User manual

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ADS-B FDL-978 Series
and FDL-978 Lite Series
Installation Manual
Part Numbers
P/N 87098-XX-XXXX
Document No. 87343

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev F
FFS Copyright © 2015 All rights reserved.
a
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http://www.freeflightsystems.com
Copyright © FreeFlight Systems. All rights reserved.

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev F
b
FFS Copyright © 2015 All rights reserved.
History of Revisions
Dates of Revision are:
Revision .….. A …………… June 13, 2013
Revision .….. B …………… July 17, 2013
Revision .….. C …………… August 26, 2013
Revision .….. D …………… May 19, 2014
Revision .….. E …………… September 16, 2014
Revision …… F …………… June 28, 2015

ADS-B FDL-978 Series and
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Document No. 87343 Rev F
FFS Copyright © 2015 All rights reserved.
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Table of Contents
SECTION 1 GENERAL INFORMATION ...............................................................................................1-1
1.1 INTRODUCTION............................................................................................................................1-1
1.2 ACRONYMS AND ABBREVIATIONS..................................................................................................1-1
1.3 ALERT SYMBOL USAGE................................................................................................................1-4
1.4 GENERAL SYSTEM DESCRIPTION..................................................................................................1-4
1.4.1 TC978 CONTROLLER............................................................................................................1-9
1.4.2UAT ANTENNA REQUIREMENTS...........................................................................................1-10
1.4.3 GPS ANTENNA REQUIREMENTS ..........................................................................................1-10
1.5 TECHNICAL CHARACTERISTICS...................................................................................................1-11
1.5.1 FDL-978 SERIES................................................................................................................1-11
1.5.2 TC978 CONTROLLER..........................................................................................................1-12
1.6 PARTS AND EQUIPMENT.............................................................................................................1-13
1.6.1 FDL-978 SERIES ITEMS......................................................................................................1-13
1.6.2 FDL-978 SERIES INSTALLATION KITS...................................................................................1-13
1.7 MATERIALS REQUIRED BUT NOT SUPPLIED.................................................................................1-16
1.7.1 LIST OF OTHER APPROVED GPS ANTENNAS ........................................................................1-16
1.7.2 FT-9000 RAMP TESTER ....................................................................................................1-16
SECTION 2 FDL-978 SERIES INSTALLATION ...................................................................................2-1
2.1 UNPACKING AND INSPECTING EQUIPMENT.....................................................................................2-1
2.2 EQUIPMENT MOUNTING................................................................................................................2-1
2.2.1 FDL-978 SERIES..................................................................................................................2-2
2.2.2 TC978 CONTROLLER............................................................................................................2-2
2.3 COOLING REQUIREMENTS............................................................................................................2-3
2.4 ELECTRICAL CONNECTIONS .........................................................................................................2-3
2.4.1 INTERFACE –DB-44 PINOUT .................................................................................................2-3
2.5 INTERFACE DETAILS ....................................................................................................................2-5
2.5.1 POWER INPUT.......................................................................................................................2-5
2.5.2 PERSONALITY MODULE .........................................................................................................2-5
2.5.3 STATUS LEDS......................................................................................................................2-6
2.5.4 REMOTE POWER CONTROL ...................................................................................................2-7
2.5.5 TC978 CONTROLLER INTERFACE...........................................................................................2-7
2.5.6 CONFIGURABLE SERIAL INTERFACES......................................................................................2-8
2.5.6.1 Serial Ports – RS-232/RS-422..................................................................................................2-8
2.5.6.2 ARINC 429 Ports......................................................................................................................2-9

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2.5.7 DISCRETE INPUTS .................................................................................................................2-9
2.5.7.1Air/Ground Input .....................................................................................................................2-10
2.5.7.2 Traffic Test Input.....................................................................................................................2-10
2.5.7.3 Anonymous Mode Input..........................................................................................................2-10
2.5.8 DISCRETE OUTPUT .............................................................................................................2-11
2.5.8.1 UAT Status Output..................................................................................................................2-11
2.5.9 TX SUPPRESSION OUTPUT..................................................................................................2-11
2.5.10 TIME MARK INPUT/OUTPUT..................................................................................................2-11
2.5.11 MAINTENANCE PORT INTERFACE .........................................................................................2-12
2.6 TC978 CONTROLLER ELECTRICAL CONNECTIONS.......................................................................2-13
2.6.1 TC978 INTERFACE –DB-9 PINOUT......................................................................................2-13
2.7 TC978 CONTROLLER INTERFACE DETAILS..................................................................................2-13
2.7.1 POWER...............................................................................................................................2-13
2.7.2 REMOTE ON.......................................................................................................................2-13
2.7.3 TMAP BUS.........................................................................................................................2-14
2.7.4 ALTITUDE OUT....................................................................................................................2-14
2.7.5 TC978 CONNECTIONS ........................................................................................................2-14
2.8 PERSONALITY MODULE INSTALLATION ........................................................................................2-14
2.9 WIRING CONSIDERATIONS..........................................................................................................2-16
2.10 UAT ANTENNA INSTALLATION ....................................................................................................2-16
2.10.1 UAT ANTENNA GROUND PLANE...........................................................................................2-17
2.10.2 UAT ANTENNA CABLE.........................................................................................................2-17
2.11 GPS ANTENNA INSTALLATION....................................................................................................2-18
2.11.1 ANTENNA POWER ...............................................................................................................2-19
2.11.2 RECOMMENDED CABLE .......................................................................................................2-19
2.11.3 SATCOM COMPATIBILITY...................................................................................................2-19
2.12 TC978 STATIC PRESSURE CONNECTION....................................................................................2-19
2.13 EQUIPMENT LIMITATIONS ...........................................................................................................2-20
2.14 DEPARTMENT OF COMMERCE COMPLIANCE................................................................................2-21
SECTION 3 FDL-978 SERIES CONFIGURATION AND CHECKOUT.................................................3-2
3.1 GENERAL....................................................................................................................................3-2
3.1.1 CONTINUED AIRWORTHINESS REQUIREMENTS........................................................................3-2
3.1.2 TC978 CONTROLLER OPERATION..........................................................................................3-2
3.1.2.1 Display......................................................................................................................................3-3
3.1.2.2 Mode Selection Knob................................................................................................................3-3
3.1.2.3 Push Buttons ............................................................................................................................3-5

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3.1.2.4 Code Knob................................................................................................................................3-8
3.1.2.5 Warning Messages...................................................................................................................3-8
3.1.2.6 Fault Annunciation....................................................................................................................3-8
3.2 PRELIMINARY CHECKOUT.............................................................................................................3-8
3.3 INSTALLATION SETUP AND CONFIGURATION..................................................................................3-9
3.3.1 FDL-978-XVR CONFIGURATION ITEM SUMMARY..................................................................3-10
3.3.2 FDL-978 SERIES SERIAL AND ARINC PORT CONFIGURATION DETAILS.................................3-12
3.3.2.1 Serial Port Input Configuration................................................................................................3-15
3.3.2.2 Serial Port Output Configuration.............................................................................................3-17
3.3.2.3 ARINC 429 Port Input Configuration.......................................................................................3-18
3.3.2.4 ARINC 429 Port Output Configuration....................................................................................3-21
3.4 MPI MODULE OVERVIEW ...........................................................................................................3-24
3.4.1 MPI MODULE......................................................................................................................3-24
3.4.2 ADS-B MPI APP.................................................................................................................3-24
3.5 MPI HARDWARE CONFIGURATION ..............................................................................................3-24
3.5.1 TOP COMPONENTS .............................................................................................................3-24
3.5.2 FRONT COMPONENT ...........................................................................................................3-24
3.5.2.1 Back Components ..................................................................................................................3-25
3.5.3 TERMINAL PROGRAM INTERFACE .........................................................................................3-26
3.5.3.1 MPI Serial Connection Settings ..............................................................................................3-26
3.5.3.2 MPI Wi-Fi Connection Settings...............................................................................................3-26
3.5.3.3 Initial MPI Connection.............................................................................................................3-26
3.5.4 MAINTENANCE COMMANDS..................................................................................................3-26
3.5.4.1 “help or ?” Command..............................................................................................................3-27
3.5.4.2 “ads” Command......................................................................................................................3-28
3.5.4.3 “bit” Command........................................................................................................................3-28
3.5.4.4 “comm” Command..................................................................................................................3-28
3.5.4.5 “control” Command.................................................................................................................3-29
3.5.4.6 “gps” Command......................................................................................................................3-29
3.5.4.7 “info” Command......................................................................................................................3-29
3.5.4.8 “Reset” Command ..................................................................................................................3-29
3.5.4.9 “rx status” Command ..............................................................................................................3-30
3.5.4.10 “cnfg” Command.....................................................................................................................3-31
3.5.4.11 “cnfgstatus” Command............................................................................................................3-32
3.5.4.12 “cnfg defaults” Command........................................................................................................3-32
3.5.4.13 “set” Command.......................................................................................................................3-32
3.5.4.13.1 Serial and ARINC Port Settings............................................................................................3-33

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3.5.4.13.1.1 “set serial in” Command................................................................................................3-33
3.5.4.13.1.2 “set serial out” Command..............................................................................................3-33
3.5.4.13.1.3 “set arinc in” Command.................................................................................................3-34
3.5.4.13.1.4 “set arinc out” Command ..............................................................................................3-34
3.5.4.13.2 ADS-B Transmit Settings......................................................................................................3-35
3.5.4.13.2.1 “set addr” Command.....................................................................................................3-35
3.5.4.13.2.2 “set call sign” Command...............................................................................................3-35
3.5.4.13.2.3 “set gps” Command......................................................................................................3-35
3.5.4.13.2.4 “set nacv” Command.....................................................................................................3-36
3.5.4.13.2.5 Set gps “set rx” Command............................................................................................3-36
3.5.4.13.2.6 “set emit cat” Command................................................................................................3-37
3.5.4.13.2.7 “set squat” Command ...................................................................................................3-37
3.5.4.13.2.8 “set threshold” Command .............................................................................................3-38
3.5.4.13.2.9 “set acsize” Command..................................................................................................3-38
3.5.4.13.2.10 “set uatant” Command..................................................................................................3-38
3.5.4.13.2.11 “set gpsant” Command .................................................................................................3-39
3.5.4.13.2.12 “set modeArx” Command..............................................................................................3-39
3.5.4.13.2.13 “set disableSquawkTx” Command................................................................................3-39
3.5.4.13.3 Display Output Settings.........................................................................................................3-40
3.5.4.13.3.1 “set max trgs” Command ..............................................................................................3-40
3.5.4.13.3.2 “set cheltonCSA” Command.........................................................................................3-40
3.5.4.13.3.3 “set trafVelVal” Command.............................................................................................3-40
3.5.4.13.3.4 “set displayout” .............................................................................................................3-41
3.6 CONFIGURATION AND SETUP USING TC978................................................................................3-42
3.6.1 ENTERING CONFIGURATION MODE.......................................................................................3-42
3.6.2 FDL-978-XVR CONFIGURATION MODE OPERATION.............................................................3-42
3.6.2.1 Aircraft Mode S (or ICAO) Address.........................................................................................3-43
3.6.2.2 VFR Squawk Code .................................................................................................................3-43
3.6.2.3 VFR Flight ID..........................................................................................................................3-43
3.6.2.4 Groundspeed Threshold.........................................................................................................3-44
3.6.2.5 Aircraft (Emitter) Category......................................................................................................3-45
3.6.2.6 Squat Switch Type..................................................................................................................3-45
3.6.2.7 Serial IN Channel X Data Type...............................................................................................3-46
3.6.2.8 Serial IN Channel X Line Speed.............................................................................................3-47
3.6.2.9 Serial OUT Channel X Data Type...........................................................................................3-47
3.6.2.10 Serial OUT Channel X Line Speed.........................................................................................3-48
3.6.2.11 ARINC IN Channel X Data Type.............................................................................................3-48
3.6.2.12 ARINC IN Channel X Interface Speed....................................................................................3-49

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3.6.2.13 ARINC OUT Chan 1 Data Type..............................................................................................3-49
3.6.2.14 ARINC OUT Chan 1 Interface Speed.....................................................................................3-50
3.6.2.15 Select Max Targets Output.....................................................................................................3-50
3.6.2.16 GPS Certification....................................................................................................................3-51
3.6.2.17 GPS NAC Velocity..................................................................................................................3-51
3.6.2.18 Aircraft Length ........................................................................................................................3-52
3.6.2.19 Aircraft Width..........................................................................................................................3-52
3.6.2.20 GPS Reference Position Offset ..............................................................................................3-53
3.6.2.21 Mode A/C Receiver Sets Squawk...........................................................................................3-54
3.6.2.22 1090 MHz Receiver Installed..................................................................................................3-54
3.6.2.23 UAT Receiver Installed...........................................................................................................3-54
3.6.2.24 UAT Antenna Diversity............................................................................................................3-55
3.6.2.25 UAT Antenna Check Ground..................................................................................................3-55
3.7 TC978 TEST AND CALIBRATION .................................................................................................3-56
3.7.1 LOCAL VOLTAGE SUPPLY TEST............................................................................................3-56
3.7.2 TC978 ALTITUDE ENCODER CALIBRATION ...........................................................................3-56
3.7.2.1 Calibration Equipment.............................................................................................................3-56
3.7.2.2 Calibration Procedure.............................................................................................................3-56
3.7.3 PRESSURE ALTITUDE REPORTED.........................................................................................3-58
SECTION 4 TROUBLESHOOTING.......................................................................................................4-1
4.1 GENERAL....................................................................................................................................4-1
4.2 FDL-978-XVR LED TROUBLESHOOTING PROCEDURE..................................................................4-1
4.2.1 UAT STATUS LED/DISCRETE FAULT INDICATIONS..................................................................4-2
4.3 WARNING MESSAGES..................................................................................................................4-3
4.3.1 TC978 WARNING MESSAGE TROUBLESHOOTING ...................................................................4-3
SECTION 5 RTCA/DO-160 ENVIRONMENTAL QUALIFICATIONS ...................................................5-1
5.1 FDL-978 EQUIPMENT AND UAT DO-160 QUALIFICATION..............................................................5-1
5.2 TC978 CONTROLLER DO-160 QUALIFICATION .............................................................................5-2
SECTION 6 SERIAL INTERFACE SPECIFICATIONS.........................................................................6-1
6.1.1 ALTITUDE ENCODER FORMAT ................................................................................................6-1
6.1.2 AIR DATA COMPUTER/SENSOR FORMAT ................................................................................6-1
SECTION 7 ADS-B COMPLIANCE.......................................................................................................7-1
SECTION 8 INSTALLATION DRAWINGS............................................................................................8-1
8.1 DIMENSIONS................................................................................................................................8-1
8.2 TC978 CONTROLLER CUT-OUT OPTIONS .....................................................................................8-2
SECTION 9 TYPICAL INTERCONNECT DIAGRAMS .........................................................................9-1

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SECTION 10 MAINTENANCE INTERFACE DIAGRAMS ....................................................................10-1
SECTION 11 WARNING DISCLAIMER ................................................................................................11-1
SECTION 12 FDL-978 LITE SERIES....................................................................................................12-1
12.1 GENERAL SYSTEM DESCRIPTION................................................................................................12-1
12.2 TECHNICAL CHARACTERISTICS...................................................................................................12-4
12.3 PARTS AND EQUIPMENT.............................................................................................................12-5
12.3.1 FDL-978 LITE SERIES ITEMS...............................................................................................12-5
12.4 INSTALLATION............................................................................................................................12-7
12.5 UNPACKING AND INSPECTING EQUIPMENT...................................................................................12-7
12.5.1 EQUIPMENT MOUNTING.......................................................................................................12-7
12.6 COOLING REQUIREMENTS..........................................................................................................12-7
12.7 ELECTRICAL CONNECTIONS .......................................................................................................12-8
12.7.1 INTERFACE –DB-44 PINOUT ...............................................................................................12-8
12.7.2 INTERFACE DETAILS............................................................................................................12-9
12.7.3 POWER INPUT.....................................................................................................................12-9
12.7.4 STATUS LEDS....................................................................................................................12-9
12.7.5 REMOTE POWER CONTROL .................................................................................................12-9
12.7.6 TC978 CONTROLLER INTERFACE.........................................................................................12-9
12.7.7 CONTROL DATA INTERFACE.................................................................................................12-9
12.7.8 ALTITUDE INPUT DATA INTERFACE .....................................................................................12-10
12.7.9 DISCRETE INPUTS .............................................................................................................12-10
12.7.9.1 Air/Ground Input ...................................................................................................................12-10
12.7.9.2 Anonymous Mode Input........................................................................................................12-10
12.7.10 DISCRETE OUTPUT ...........................................................................................................12-10
12.7.11 WI-FI MODULE OR MAINTENANCE PORT INTERFACE ...........................................................12-11
12.8 TC978 CONTROLLER ELECTRICAL CONNECTIONS.....................................................................12-11
12.9 WIRING CONSIDERATIONS........................................................................................................12-11
12.10 UAT ANTENNA INSTALLATION ..................................................................................................12-11
12.11 CONFIGURATION AND CHECKOUT .............................................................................................12-11
12.12 INSTALLATION SETUP AND CONFIGURATION..............................................................................12-12
12.12.1 FDL-978 LITE SERIES CONFIGURATION ITEM SUMMARY.....................................................12-12
12.12.2 FDL-978 LITE SERIES INTERFACE CONFIGURATION DETAILS ..............................................12-12
12.12.2.1 Control Data Interface...........................................................................................................12-12
12.12.2.2 Altitude Input Interface..........................................................................................................12-13
12.12.2.3 Wi-Fi Module or Maintenance Port Interface.........................................................................12-13
12.13 CONFIGURATION AND SETUP USING TC978..............................................................................12-14