FreeFlight ADS-B FDL-978 Series User manual

This document contains FreeFlight Systems proprietary information. It is loaned for limited purposes only and
remains the property of FreeFlight Systems. It may not be reproduced in whole or in part without written consent
of FreeFlight Systems and must not be disclosed to persons not having need of such disclosure consistent with
the purpose of the loan. The document is to be returned to FreeFlight Systems upon request and/or upon
completion of the use for which it was loaned.
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 G
FFS Copyright © 2016 All rights reserved. a
Proprietary Information
This document contains FreeFlight Systems proprietary information. It is furnished to FreeFlight
Systems customers by the rights expressly granted by contract and may not, in whole or in part,
be duplicated or its contents disclosed to unauthorized personnel without prior written consent
from FreeFlight Systems.
The information provided in this document is subject to change without notice. Please visit the
FreeFlight Systems website (http://www.freeflightsystems.com) or contact Product Support for
updated materials regarding your products.
For Product Support, Repair, or Sales, please contact us directly or an authorized FreeFlight
Systems Dealer.
Product Support Department:
Phone: [phone], ext. 503
Direct: +1.254.662.7083
Toll Free: 1.800.487.4662, ext. 503
Email: [e-mail]
Repair Department:
Phone: [phone], ext. 502
Direct: +1.254.662.7082
Toll Free: 1.800.487.4662, ext. 502
Email: [e-mail]
Sales Department:
Phone: [phone], ext. 501
Direct: +1.254.662.7081
Toll Free: 1.800.487.4662, ext. 501
Email: [e-mail]
Our normal business hours are Monday – Friday, 8 a.m. to 5 p.m., U.S. CST (UTC -06:00).
FreeFlight Systems
3700 Interstate 35 S.
Waco, TX 76706
+1 254.662.0000
+1 800.487.4662
http://www.freeflightsystems.com
Copyright © FreeFlight Systems. All rights reserved.

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
b FFS Copyright © 2016 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
Revision …… G …………… April 8, 2016

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
FFS Copyright © 2016 All rights reserved. i
Table of Contents
SECTION 1 GENERAL INFORMATION ............................................................................................... 1-1
1.1 INTRODUCTION ............................................................................................................................ 1-1
1.2 ACRONYMS AND ABBREVIATIONS .................................................................................................. 1-2
1.3 ALERT SYMBOL USAGE ................................................................................................................ 1-4
1.4 GENERAL SYSTEM DESCRIPTION .................................................................................................. 1-5
1.4.1 TC978 CONTROLLER .......................................................................................................... 1-10
1.4.2 UAT ANTENNA REQUIREMENTS ........................................................................................... 1-11
1.4.3 GPS ANTENNA REQUIREMENTS .......................................................................................... 1-11
1.5 TECHNICAL CHARACTERISTICS ................................................................................................... 1-12
1.5.1 FDL-978 SERIES ................................................................................................................ 1-12
1.5.2 TC978 CONTROLLER .......................................................................................................... 1-13
1.6 PARTS AND EQUIPMENT ............................................................................................................. 1-14
1.6.1 FDL-978 SERIES ITEMS ...................................................................................................... 1-14
1.6.2 FDL-978 SERIES INSTALLATION KITS ................................................................................... 1-14
1.7 MATERIALS REQUIRED BUT NOT SUPPLIED ................................................................................. 1-17
1.7.1 LIST OF OTHER APPROVED GPS ANTENNAS ........................................................................ 1-17
1.7.2 FT-9000 RAMP TESTER .................................................................................................... 1-18
SECTION 2 FDL-978 SERIES INSTALLATION ................................................................................... 2-2
2.1 UNPACKING AND INSPECTING EQUIPMENT ..................................................................................... 2-2
2.2 EQUIPMENT MOUNTING ................................................................................................................ 2-2
2.2.1 FDL-978 SERIES .................................................................................................................. 2-3
2.2.2 TC978 CONTROLLER ............................................................................................................ 2-4
2.3 COOLING REQUIREMENTS ............................................................................................................ 2-4
2.4 ELECTRICAL CONNECTIONS ......................................................................................................... 2-5
2.4.1 INTERFACE – DB-44 PINOUT ................................................................................................. 2-5
2.5 INTERFACE DETAILS .................................................................................................................... 2-6
2.5.1 POWER INPUT ....................................................................................................................... 2-6
2.5.2 PERSONALITY MODULE ......................................................................................................... 2-7
2.5.3 STATUS LEDS ...................................................................................................................... 2-7
2.5.4 REMOTE POWER CONTROL ................................................................................................... 2-8
2.5.5 TC978 CONTROLLER INTERFACE........................................................................................... 2-8
2.5.6 CONFIGURABLE SERIAL INTERFACES ...................................................................................... 2-8
2.5.6.1 Serial Ports – RS-232/RS-422 .................................................................................................. 2-9
2.5.6.2 ARINC 429 Ports .................................................................................................................... 2-10
2.5.7 DISCRETE INPUTS ............................................................................................................... 2-10

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
ii FFS Copyright © 2016 All rights reserved.
2.5.7.1 Air/Ground Input ..................................................................................................................... 2-11
2.5.7.2 Traffic Test Input ..................................................................................................................... 2-11
2.5.7.3 Anonymous Mode Input .......................................................................................................... 2-11
2.5.8 DISCRETE OUTPUT ............................................................................................................. 2-12
2.5.8.1 UAT Status Output .................................................................................................................. 2-12
2.5.8.2 TX Suppression Output........................................................................................................... 2-12
2.5.9 TIME MARK INPUT/OUTPUT .................................................................................................. 2-12
2.5.10 MAINTENANCE PORT INTERFACE ......................................................................................... 2-13
2.6 TC978 CONTROLLER ELECTRICAL CONNECTIONS....................................................................... 2-14
2.6.1 TC978 INTERFACE – DB-9 PINOUT...................................................................................... 2-14
2.7 TC978 CONTROLLER INTERFACE DETAILS .................................................................................. 2-14
2.7.1 POWER............................................................................................................................... 2-14
2.7.2 REMOTE ON ....................................................................................................................... 2-15
2.7.3 TMAP BUS ......................................................................................................................... 2-15
2.7.4 ALTITUDE OUT .................................................................................................................... 2-15
2.7.5 TC978 CONNECTIONS ........................................................................................................ 2-15
2.8 PERSONALITY MODULE INSTALLATION ........................................................................................ 2-16
2.9 WIRING CONSIDERATIONS .......................................................................................................... 2-18
2.10 UAT ANTENNA INSTALLATION .................................................................................................... 2-18
2.10.1 UAT ANTENNA GROUND PLANE........................................................................................... 2-19
2.10.2 UAT ANTENNA CABLE ......................................................................................................... 2-19
2.11 GPS ANTENNA INSTALLATION .................................................................................................... 2-20
2.11.1 ANTENNA POWER ............................................................................................................... 2-21
2.11.2 RECOMMENDED CABLE ....................................................................................................... 2-21
2.11.3 SATCOM COMPATIBILITY ................................................................................................... 2-21
2.12 TC978 STATIC PRESSURE CONNECTION .................................................................................... 2-21
2.13 EQUIPMENT LIMITATIONS ........................................................................................................... 2-22
2.13.1 NON-TSO FUNCTIONS ........................................................................................................ 2-23
2.14 DEPARTMENT OF COMMERCE COMPLIANCE ................................................................................ 2-23
SECTION 3 FDL-978 SERIES CONFIGURATION AND CHECKOUT ................................................. 3-1
3.1 GENERAL .................................................................................................................................... 3-1
3.1.1 CONTINUED AIRWORTHINESS REQUIREMENTS ........................................................................ 3-1
3.1.2 TC978 CONTROLLER OPERATION.......................................................................................... 3-1
3.1.2.1 Display ...................................................................................................................................... 3-2
3.1.2.2 Warning Messages ................................................................................................................... 3-3
3.1.2.3 Fault Annunciation .................................................................................................................... 3-3
3.2 PRELIMINARY CHECKOUT ............................................................................................................. 3-3

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
FFS Copyright © 2016 All rights reserved. iii
3.3 INSTALLATION SETUP AND CONFIGURATION .................................................................................. 3-4
3.3.1 FDL-978-XVR CONFIGURATION ITEM SUMMARY.................................................................... 3-5
3.3.2 FDL-978 SERIES SERIAL AND ARINC PORT CONFIGURATION DETAILS ................................... 3-7
3.3.2.1 Serial Port Input Configuration ................................................................................................ 3-10
3.3.2.2 Serial Port Output Configuration ............................................................................................. 3-12
3.3.2.3 ARINC 429 Port Input Configuration ....................................................................................... 3-13
3.3.2.4 ARINC 429 Port Output Configuration .................................................................................... 3-16
3.4 MPI MODULE OVERVIEW ........................................................................................................... 3-19
3.4.1 INSTALLATION ADAPTER ...................................................................................................... 3-19
3.4.2 MPI MODULE ...................................................................................................................... 3-19
3.4.3 ADS-B MPI APP ................................................................................................................. 3-19
3.5 MPI HARDWARE CONFIGURATION .............................................................................................. 3-20
3.5.1 TERMINAL PROGRAM INTERFACE ......................................................................................... 3-20
3.5.1.1 MPI Serial Connection Settings .............................................................................................. 3-21
3.5.1.2 Terminal MPI Wi-Fi Connection Settings ................................................................................ 3-21
3.5.1.3 Initial MPI Connection ............................................................................................................. 3-22
3.5.2 TERMINAL MAINTENANCE COMMANDS .................................................................................. 3-23
3.5.2.1 “help or ?” Command .............................................................................................................. 3-23
3.5.2.2 “ads” Command ...................................................................................................................... 3-24
3.5.2.3 “bit” Command ........................................................................................................................ 3-24
3.5.2.4 “comm” Command .................................................................................................................. 3-24
3.5.2.5 “control” Command ................................................................................................................. 3-25
3.5.2.6 “gps” Command ...................................................................................................................... 3-25
3.5.2.7 “info” Command ...................................................................................................................... 3-25
3.5.2.8 “Reset” Command .................................................................................................................. 3-25
3.5.2.9 “rxstatus” Command ............................................................................................................... 3-26
3.5.2.10 “cnfg” Command ..................................................................................................................... 3-27
3.5.2.11 Deleted ................................................................................................................................... 3-28
3.5.2.12 “cnfg defaults” Command ........................................................................................................ 3-28
3.5.2.13 “set” Command ....................................................................................................................... 3-29
3.5.2.13.1 Serial and ARINC Port Settings ............................................................................................ 3-29
3.5.2.13.1.1 “set serial in” Command ................................................................................................ 3-29
3.5.2.13.1.2 “set serial out” Command .............................................................................................. 3-30
3.5.2.13.1.3 “set arinc in” Command ................................................................................................. 3-31
3.5.2.13.1.4 “set arinc out” Command .............................................................................................. 3-31
3.5.2.13.2 ADS-B Transmit Settings ...................................................................................................... 3-32
3.5.2.13.2.1 “set addr” Command ..................................................................................................... 3-32
3.5.2.13.2.2 “set call sign” Command ............................................................................................... 3-32

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
iv FFS Copyright © 2016 All rights reserved.
3.5.2.13.2.3 “set gps” Command ...................................................................................................... 3-32
3.5.2.13.2.4 “set nacv” Command..................................................................................................... 3-33
3.5.2.13.2.5 Set gps “set rx” Command ............................................................................................ 3-33
3.5.2.13.2.6 “set emit cat” Command ................................................................................................ 3-34
3.5.2.13.2.7 “set squat” Command ................................................................................................... 3-34
3.5.2.13.2.8 “set threshold” Command ............................................................................................. 3-35
3.5.2.13.2.9 “set acsize” Command .................................................................................................. 3-35
3.5.2.13.2.10 “set uatant” Command .................................................................................................. 3-35
3.5.2.13.2.11 “set gpsant” Command ................................................................................................. 3-36
3.5.2.13.2.12 “set modeArx” Command .............................................................................................. 3-36
3.5.2.13.2.13 “set disableSquawkTx” Command ................................................................................ 3-36
3.5.2.13.3 Display Output Settings......................................................................................................... 3-37
3.5.2.13.3.1 “set max trgs” Command .............................................................................................. 3-37
3.5.2.13.3.2 “set cheltonCSA” Command ......................................................................................... 3-37
3.5.2.13.3.3 “set trafVelVal” Command ............................................................................................. 3-37
3.5.2.13.3.4 “set displayout” ............................................................................................................. 3-38
3.5.3 TERMINAL MAINTENANCE PORT INTERFACE SECURITY .......................................................... 3-39
3.5.3.1 “setpw” Command .................................................................................................................. 3-39
3.5.3.2 “checkpw” Command .............................................................................................................. 3-39
3.5.3.3 “resetpw” Command ............................................................................................................... 3-40
3.5.3.4 “maint ascii pw” Command ..................................................................................................... 3-40
3.5.3.5 Resetting Forgotten Password ................................................................................................ 3-40
3.6 CONFIGURATION AND SETUP USING TC978 ................................................................................ 3-41
3.6.1 ENTERING CONFIGURATION MODE ....................................................................................... 3-41
3.6.2 FDL-978-XVR CONFIGURATION MODE OPERATION ............................................................. 3-41
3.6.2.1 Aircraft Mode S (or ICAO) Address ......................................................................................... 3-42
3.6.2.2 VFR Squawk Code ................................................................................................................. 3-42
3.6.2.3 VFR Flight ID .......................................................................................................................... 3-42
3.6.2.4 Groundspeed Threshold ......................................................................................................... 3-43
3.6.2.5 Aircraft (Emitter) Category ...................................................................................................... 3-44
3.6.2.6 Squat Switch Type .................................................................................................................. 3-44
3.6.2.7 Serial IN Channel X Data Type ............................................................................................... 3-45
3.6.2.8 Serial IN Channel X Line Speed ............................................................................................. 3-46
3.6.2.9 Serial OUT Channel X Data Type ........................................................................................... 3-46
3.6.2.10 Serial OUT Channel X Line Speed ......................................................................................... 3-47
3.6.2.11 ARINC IN Channel X Data Type ............................................................................................. 3-48
3.6.2.12 ARINC IN Channel X Interface Speed .................................................................................... 3-48
3.6.2.13 ARINC OUT Chan 1 Data Type .............................................................................................. 3-49
3.6.2.14 ARINC OUT Chan 1 Interface Speed ..................................................................................... 3-49

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
FFS Copyright © 2016 All rights reserved. v
3.6.2.15 Select Max Targets Output ..................................................................................................... 3-50
3.6.2.16 GPS Certification .................................................................................................................... 3-50
3.6.2.17 GPS NAC Velocity .................................................................................................................. 3-51
3.6.2.18 Aircraft Length ........................................................................................................................ 3-51
3.6.2.19 Aircraft Width .......................................................................................................................... 3-51
3.6.2.20 GPS Reference Position Offset .............................................................................................. 3-52
3.6.2.21 Mode A/C Receiver Sets Squawk ........................................................................................... 3-53
3.6.2.22 1090 MHz Receiver Installed .................................................................................................. 3-53
3.6.2.23 UAT Receiver Installed ........................................................................................................... 3-53
3.6.2.24 UAT Antenna Diversity............................................................................................................ 3-54
3.6.2.25 UAT Antenna Check Ground .................................................................................................. 3-54
3.7 TC978 TEST AND CALIBRATION ................................................................................................. 3-55
3.7.1 LOCAL VOLTAGE SUPPLY TEST ............................................................................................ 3-55
3.7.2 TC978 ALTITUDE ENCODER CALIBRATION ........................................................................... 3-55
3.7.2.1 Calibration Equipment............................................................................................................. 3-55
3.7.2.2 Calibration Procedure ............................................................................................................. 3-55
3.7.3 PRESSURE ALTITUDE REPORTED ......................................................................................... 3-57
SECTION 4 TROUBLESHOOTING ..................................................................................................... 4-58
4.1 GENERAL .................................................................................................................................. 4-58
4.2 FDL-978-XVR LED TROUBLESHOOTING PROCEDURE ................................................................ 4-58
4.2.1 UAT STATUS LED/DISCRETE FAULT INDICATIONS ................................................................ 4-59
4.3 WARNING MESSAGES ................................................................................................................ 4-60
4.3.1 TC978 WARNING MESSAGE TROUBLESHOOTING ................................................................. 4-60
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 ............................................................................. 5-3
SECTION 6 SERIAL INTERFACE SPECIFICATIONS ......................................................................... 6-1
6.1 ALTITUDE ENCODER FORMAT ....................................................................................................... 6-1
6.2 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
9.1 TYPICAL SYSTEM CONFIGURATIONS ............................................................................................. 9-1
9.1.1 GARMIN GNS 430W/530W DISPLAY AND GPS, GTX-330 TRANSPONDER ............................. 9-1
9.1.2 CHELTON FLIGHTLOGIC DISPLAY, GSL-71 CONTROLLER, NO TRANSPONDER ......................... 9-2

ADS-B FDL-978 Series and
Lite Series Installation Manual
Document No. 87343 Rev G
vi FFS Copyright © 2016 All rights reserved.
9.1.3 ASPEN DISPLAY AND CONTROL, GTX 327 TRANSPONDER ...................................................... 9-3
9.1.4 BENDIX KING KSN 765/770 DISPLAY AND GPS, GTX-327 TRANSPONDER ............................. 9-4
9.1.5 MODE A/C TRANSPONDER, TC978 CONTROLLER................................................................... 9-5
9.1.6 GARMIN GNS 480, SL-70 TRANSPONDER, TCAS .................................................................. 9-6
9.1.7 GARMIN MX-20 DISPLAY AND CONTROL, NO TRANSPONDER .................................................. 9-7
9.1.8 GARMIN GMX-200 DISPLAY, GTX-330 TRANSPONDER .......................................................... 9-8
9.1.9 GARMIN GTX-330ES TRANSPONDER WITH FDL-978 GPS SOURCE ....................................... 9-9
9.2 EQUIPMENT SPECIFIC INSTALLATIONS ......................................................................................... 9-11
9.2.1 FREEFLIGHT SYSTEMS 1201 GPS ....................................................................................... 9-11
9.2.2 FREEFLIGHT SYSTEMS 1203C GPS .................................................................................... 9-11
9.3 EQUIPMENT COMPATIBILITY AND FUNCTIONS .............................................................................. 9-12
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
12.7.11.1 Initial MPI Connection ........................................................................................................... 12-11