FreeFlight ADS-B FDL-DB Dual Band Series Service manual

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ADS-B FDL-DB Dual Band Series
Installation Information
Part Numbers
P/N 87334-XX-XXXX
Document No. 88552
Disclaimer: This manual revision is a controlled engineering release copy which is currently under review
and pending TSO approval. This document has been loaned only to specific customers and must not be
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ADS-B FDL-DB Dual Band Series
Installation Information
Document No: 88552 Rev A
FFS Copyright © 2020 All rights reserved.
a
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Copyright © FreeFlight Systems. All rights reserved.

ADS-B FDL-DB Dual Band Series
Installation Manual
Document No. 88552 Rev A
b
FFS Copyright © 2020 All rights reserved.
History of Revisions
Dates of Revision are:
Revision –A (Initial Release).........………………………….August-20-2020

ADS-B FDL-DB Dual Band Series
Installation Manual
Document No. 88552 Rev A
FFS Copyright © 2020 All rights reserved.
i
Table of Contents
SECTION 1 GENERAL INFORMATION ...............................................................................................1-1
1.1 INTRODUCTION............................................................................................................................1-1
1.1.1 EQUIPMENT LIMITATIONS.......................................................................................................1-1
1.1.2 FCC WARNING.....................................................................................................................1-2
1.1.3 NON-TSO FUNCTIONS ..........................................................................................................1-2
1.2 ACRONYMS AND ABBREVIATIONS..................................................................................................1-3
1.3 ALERT SYMBOL USAGE................................................................................................................1-5
1.4 GENERAL SYSTEM DESCRIPTION..................................................................................................1-6
1.4.1 TC978 CONTROLLER............................................................................................................1-7
1.4.2 UAT ANTENNA REQUIREMENTS.............................................................................................1-8
1.4.3 GPS ANTENNA REQUIREMENTS ............................................................................................1-8
1.5 TECHNICAL CHARACTERISTICS.....................................................................................................1-9
1.5.1 FDL-DB SERIES...................................................................................................................1-9
1.5.2 TC978 CONTROLLER..........................................................................................................1-10
1.6 PARTS AND EQUIPMENT.............................................................................................................1-11
1.6.1 FDL-DB SERIES ITEMS.......................................................................................................1-11
1.7 REQUIRED MATERIALS NOT SUPPLIED........................................................................................1-12
1.7.1 LIST OF OTHER APPROVED GPS ANTENNAS ........................................................................1-12
1.7.2 FT-9000 RAMP TESTER ....................................................................................................1-13
SECTION 2 FDL-DB DUAL BAND SERIES INTERFACES...............................................................2-14
2.1 UNPACKING AND INSPECTING EQUIPMENT...................................................................................2-14
2.2 EQUIPMENT MOUNTING..............................................................................................................2-14
2.2.1 FDL-DB SERIES.................................................................................................................2-15
2.2.2 TC978 CONTROLLER..........................................................................................................2-16
2.3 COOLING REQUIREMENTS..........................................................................................................2-16
2.4 ELECTRICAL CONNECTIONS .......................................................................................................2-17
2.4.1 INTERFACE –DB-62 PINOUT ...............................................................................................2-17
2.5 INTERFACE DETAILS ..................................................................................................................2-19
2.5.1 POWER INPUT.....................................................................................................................2-19
2.5.2 PERSONALITY MODULE .......................................................................................................2-20
2.5.3 STATUS LEDS....................................................................................................................2-20
2.5.4 REMOTE POWER CONTROL .................................................................................................2-21
2.5.5 TC978 CONTROLLER INTERFACE.........................................................................................2-21
2.5.6 CONFIGURABLE SERIAL INTERFACES....................................................................................2-21
2.5.6.1 Serial Ports –RS-232/RS-422................................................................................................2-22

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2.5.6.1.1 RS-232 to RS-485/-422 Serial Converters............................................................................2-23
2.5.6.2 ARINC 429 Ports ....................................................................................................................2-23
2.5.7 DISCRETE INPUTS...............................................................................................................2-24
2.5.7.1 Air/Ground Input .....................................................................................................................2-25
2.5.7.2 Traffic Test Input.....................................................................................................................2-25
2.5.7.3 Anonymous Mode Input..........................................................................................................2-25
2.5.8 DISCRETE OUTPUT .............................................................................................................2-26
2.5.8.1 UAT Status Output..................................................................................................................2-26
2.5.8.2 TX Suppression Output...........................................................................................................2-26
2.5.9 TIME MARK INPUT/OUTPUT..................................................................................................2-26
2.5.10 MAINTENANCE PORT INTERFACE .........................................................................................2-27
2.5.10.1 USB Interface .........................................................................................................................2-28
2.5.10.2 Ethernet Interface ...................................................................................................................2-28
2.5.11 AUDIO INTERFACE (FUTURE RELEASE).................................................................................2-30
2.6 TC978 CONTROLLER ELECTRICAL CONNECTIONS.......................................................................2-30
2.6.1 TC978 INTERFACE –DB-9 PINOUT......................................................................................2-30
2.7 TC978 CONTROLLER INTERFACE DETAILS..................................................................................2-30
2.7.1 POWER...............................................................................................................................2-30
2.7.2 REMOTE ON.......................................................................................................................2-30
2.7.3 TMAP BUS.........................................................................................................................2-30
2.7.4 ALTITUDE OUT....................................................................................................................2-31
2.7.5 TC978 CONNECTIONS ........................................................................................................2-31
2.8 PERSONALITY MODULE INSTALLATION ........................................................................................2-32
2.9 WIRING CONSIDERATIONS..........................................................................................................2-34
2.10 UAT ANTENNA INSTALLATION ....................................................................................................2-34
2.10.1 UAT ANTENNA GROUND PLANE...........................................................................................2-35
2.10.2 UAT ANTENNA CABLE.........................................................................................................2-35
2.11 GPS ANTENNA INSTALLATION....................................................................................................2-36
2.11.1 ANTENNA POWER ...............................................................................................................2-37
2.11.2 RECOMMENDED CABLE FOR GPS........................................................................................2-37
2.11.3 SATCOM COMPATIBILITY...................................................................................................2-37
2.12 TC978 STATIC PRESSURE CONNECTION....................................................................................2-37
2.13 DEPARTMENT OF COMMERCE COMPLIANCE................................................................................2-38
SECTION 3 RTCA/DO-160 ENVIRONMENTAL QUALIFICATIONS ...................................................3-1
3.1 FDL-DB SERIES EQUIPMENT AND UAT DO-160 QUALIFICATION...................................................3-1
SECTION 4 SERIAL INTERFACE SPECIFICATIONS.........................................................................4-3
4.1 ALTITUDE ENCODER FORMAT.......................................................................................................4-3

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4.2 AIR DATA COMPUTER/SENSOR FORMAT.......................................................................................4-3
SECTION 5 FDL-DB DUAL BAND SERIES PORT CONFIGURATION...............................................5-5
5.1 GENERAL....................................................................................................................................5-5
5.1.1 FDL-DB DUAL BAND SERIES SERIAL,ARINC AND NETWORK PORT CONFIGURATION DETAILS 5-5
5.1.1.1 Serial Port Input Configuration..................................................................................................5-8
5.1.1.2 Serial Port Output Configuration.............................................................................................5-10
5.1.1.3 ARINC 429 Port Input Configuration.......................................................................................5-11
5.1.1.4 ARINC 429 Port Output Configuration....................................................................................5-13
5.1.1.5 Network Server Port Connection Configuration Details..........................................................5-15
5.1.1.5.1 UDP Connection ...................................................................................................................5-15
5.1.1.5.2 TCP Connection....................................................................................................................5-15
5.1.1.6 Network Server Port Input Configuration Details ....................................................................5-16
5.1.1.7 Network Server Port Functionality Configuration Details ........................................................5-16
5.2 MAINTENANCE PORT INTERFACE (MPI) HARDWARE CONFIGURATION ..........................................5-18
5.2.1 TERMINAL PROGRAM INTERFACE .........................................................................................5-18
5.2.1.1 Terminal MPI Network Connection Settings ...........................................................................5-18
5.2.1.2 Initial MPI Connection using the Telnet Remote Network Server Port....................................5-21
5.2.2 TERMINAL MAINTENANCE COMMANDS..................................................................................5-22
5.2.2.1 “help or ?” Command ..............................................................................................................5-22
5.2.2.2 “ads” Command ......................................................................................................................5-24
5.2.2.3 “bit” Command ........................................................................................................................5-24
5.2.2.4 “comm” Command ..................................................................................................................5-24
5.2.2.5 “control” Command .................................................................................................................5-26
5.2.2.6 “gps” Command ......................................................................................................................5-26
5.2.2.7 “info” Command ......................................................................................................................5-26
5.2.2.8 “Reset” Command ..................................................................................................................5-27
5.2.2.9 “rxstatus” Command ...............................................................................................................5-28
5.2.2.10 “cnfg” Command .....................................................................................................................5-29
5.2.2.11 “cnfg defaults” Command........................................................................................................5-30
5.2.2.12 “set” Command .......................................................................................................................5-31
5.2.2.12.1 “set hostname” Command.....................................................................................................5-31
5.2.2.12.2 “set net” Command ...............................................................................................................5-31
5.2.2.12.3 “set netserver” Command .....................................................................................................5-32
5.2.2.12.4 Display Output Settings.........................................................................................................5-33
5.2.2.12.4.1 “set max trgs” Command ..............................................................................................5-33
5.2.2.12.4.2 “set cheltonCSA” Command .........................................................................................5-33
5.2.2.12.4.3 “set trafVelVal” Command.............................................................................................5-34
5.2.2.12.4.4 “set displayout” .............................................................................................................5-34

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5.3 CONFIGURATION AND SETUP USING TC978................................................................................5-35
5.3.1 ENTERING CONFIGURATION MODE.......................................................................................5-35
5.3.2 FDL-DB-XVR CONFIGURATION MODE OPERATION..............................................................5-36
5.3.2.1 Aircraft Mode S (or ICAO) Address.........................................................................................5-37
5.3.2.2 VFR Squawk Code .................................................................................................................5-37
5.3.2.3 VFR Flight ID..........................................................................................................................5-37
5.3.2.4 Groundspeed Threshold.........................................................................................................5-38
5.3.2.5 Aircraft (Emitter) Category......................................................................................................5-39
5.3.2.6 Squat Switch Type..................................................................................................................5-39
5.3.2.7 Serial IN Channel X Data Type...............................................................................................5-40
5.3.2.8 Serial IN Channel X Line Speed .............................................................................................5-41
5.3.2.9 Serial OUT Channel X Data Type...........................................................................................5-41
5.3.2.10 Serial OUT Channel X Line Speed.........................................................................................5-42
5.3.2.11 ARINC IN Channel X Data Type.............................................................................................5-43
5.3.2.12 ARINC IN Channel X Interface Speed....................................................................................5-43
5.3.2.13 ARINC OUT Chan 1 Data Type..............................................................................................5-44
5.3.2.14 ARINC OUT Chan 1 Interface Speed .....................................................................................5-44
5.3.2.15 Select Max Targets Output.....................................................................................................5-45
5.3.2.16 GPS Certification ....................................................................................................................5-45
5.3.2.17 GPS NAC Velocity..................................................................................................................5-46
5.3.2.18 Aircraft Length ........................................................................................................................5-46
5.3.2.19 Aircraft Width ..........................................................................................................................5-46
5.3.2.20 GPS Reference Position Offset ..............................................................................................5-47
5.3.2.21 Mode A/C Receiver Sets Squawk...........................................................................................5-48
5.3.2.22 1090 MHz Receiver Installed..................................................................................................5-48
5.3.2.23 UAT Receiver Installed...........................................................................................................5-49
5.3.2.24 UAT Antenna Diversity............................................................................................................5-49
5.3.2.25 UAT Antenna Check Ground..................................................................................................5-50
5.4 TC978 TEST AND CALIBRATION .................................................................................................5-51
5.4.1 LOCAL VOLTAGE SUPPLY TEST............................................................................................5-51
5.4.2 TC978 ALTITUDE ENCODER CALIBRATION ...........................................................................5-51
5.4.2.1 Calibration Equipment.............................................................................................................5-51
5.4.2.2 Calibration Procedure.............................................................................................................5-51
5.4.3 PRESSURE ALTITUDE REPORTED.........................................................................................5-53
SECTION 6 TROUBLESHOOTING.....................................................................................................6-54
6.1 GENERAL..................................................................................................................................6-54
6.2 FDL-DB SERIES LED TROUBLESHOOTING PROCEDURE .............................................................6-54
6.2.1 UAT STATUS LED/DISCRETE FAULT INDICATIONS................................................................6-55

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FFS Copyright © 2020 All rights reserved.
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6.3 WARNING MESSAGES................................................................................................................6-56
6.3.1 TC978 WARNING MESSAGE TROUBLESHOOTING .................................................................6-56
SECTION 7 TYPICAL INTERCONNECT DIAGRAMS .......................................................................7-58
7.1 TYPICAL SYSTEM CONFIGURATIONS ...........................................................................................7-58
7.1.1 GARMIN GNS 430W/530W DISPLAY AND GPS, GTX-330 TRANSPONDER .............................7-1
7.1.2 CHELTON FLIGHTLOGIC DISPLAY,GSL-71 CONTROLLER,NO TRANSPONDER .........................7-2
7.1.3 ASPEN DISPLAY AND CONTROL,GTX 327 TRANSPONDER......................................................7-3
7.1.4 MODE A/C TRANSPONDER,TC978 CONTROLLER...................................................................7-4
7.1.5 GARMIN GNS 480, SL-70 TRANSPONDER,TCAS..................................................................7-5
7.1.6 GARMIN GMX-200 DISPLAY,GTX-330 TRANSPONDER..........................................................7-7
7.1.7 GARMIN GTX-330ES TRANSPONDER WITH FDL-DB-XVR GPS SOURCE ...............................7-8
7.2 EQUIPMENT SPECIFIC INSTALLATIONS...........................................................................................7-1
7.2.1 FREEFLIGHT SYSTEMS 1201 GPS.........................................................................................7-1
7.2.2 FREEFLIGHT SYSTEMS 1203C GPS......................................................................................7-1
7.3 EQUIPMENT COMPATIBILITY AND FUNCTIONS ................................................................................7-1
SECTION 8 MAINTENANCE INTERFACE DIAGRAMS ......................................................................8-1
SECTION 9 WARNING DISCLAIMER ..................................................................................................9-1
SECTION 10 LIMITED WARRANTY.....................................................................................................10-2
List of Figures
FIGURE 1: TC978 CONTROLLER ...................................................................................................................1-7
FIGURE 2: FDL-DB SERIES MOUNTING DIMENSIONS....................................................................................2-15
FIGURE 3: TC978 DIMENSIONS...................................................................................................................2-16
FIGURE 4: FDC-485/422 SERIAL CONVERTER.............................................................................................2-23
FIGURE 5: INLINE MPI CONNECTOR AND COMPATIBLE MPI DEVICES ............................................................2-27
FIGURE 6: PERSONALITY MODULE ASSEMBLY..............................................................................................2-33
FIGURE 7: STATIC LINE CONNECTION..........................................................................................................2-38
FIGURE 8: TERA TERM TERMINAL SETUP.....................................................................................................5-18
FIGURE 9: TERA TERM NETWORK CONNECTION SETTINGS USING TELNET.....................................................5-19
FIGURE 10: NETWORK HARDWARE CONNECTIONS.......................................................................................5-20
FIGURE 11: TERA TERM NETWORK CONNECTION SETTINGS USING A REMOTE NETWORK SERVER PORT........5-21
FIGURE 12: EXAMPLE TERA TERM NETWORK CONNECTION SETTINGS USING TELNET....................................5-21
FIGURE 13: FDL-DB SERIES HELP MENU....................................................................................................5-23
FIGURE 14: FDL-DB SERIES ADS MENU ......................................................................................................5-24
FIGURE 15: FDL-DB SERIES BIT MENU........................................................................................................5-24
FIGURE 16: FDL-DB SERIES COMM MENU...................................................................................................5-25

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FFS Copyright © 2020 All rights reserved.
FIGURE 17: FDL-DB SERIES CONTROL MENU..............................................................................................5-26
FIGURE 18: FDL-DB SERIES GPS MENU......................................................................................................5-26
FIGURE 19: FDL-DB SERIES INFO MENU .....................................................................................................5-27
FIGURE 20: FDL-DB SERIES RESET COMMAND ...........................................................................................5-27
FIGURE 21: FDL-DB SERIES RXSTATUS COMMAND DISPLAY.........................................................................5-28
FIGURE 22: FDL-DB SERIES CNFG MENU....................................................................................................5-29
FIGURE 23: FDL-DB SERIES CNFG DEFAULTS COMMAND .............................................................................5-30
FIGURE 24: FDL-DB SERIES SET HELP MENU..............................................................................................5-31
FIGURE 25: FDL-DB SERIES SET HOSTNAME HELP MENU.............................................................................5-31
FIGURE 26: FDL-DB SERIES SET NET HELP MENU........................................................................................5-32
FIGURE 27: FDL-DB SERIES SET NETSERVER HELP MENU............................................................................5-33
FIGURE 28: FDL-DB SERIES SET MAX TRGS COMMAND................................................................................5-33
FIGURE 29: FDL-DB SERIES SET CHELTONCSA COMMAND..........................................................................5-34
FIGURE 30: FDL-DB SERIES SET TRAFFVELVAL COMMAND..........................................................................5-34
FIGURE 31: FDL-DB SET DISPLAYOUT COMMAND.........................................................................................5-35
FIGURE 32: GARMIN GNS 430W/530W DISPLAY AND GPS, GTX-330 TRANSPONDER...................................7-1
FIGURE 33: CHELTON FLIGHTLOGIC DISPLAY,GSL-71 CONTROLLER.............................................................7-2
FIGURE 34: ASPEN DISPLAY AND CONTROL,GTX 327 TRANSPONDER............................................................7-3
FIGURE 35: MODE A/C TRANSPONDER,TC978 CONTROLLER........................................................................7-4
FIGURE 36: GARMIN GNS 480, SL-70 TRANSPONDER,TCAS .......................................................................7-5
FIGURE 37: GARMIN MX-20 DISPLAY AND CONTROL,NO TRANSPONDER........................................................7-6
FIGURE 38: GARMIN GMX-200 DISPLAY,GTX-330 TRANSPONDER ...............................................................7-7
FIGURE 39: GTX-330ES TRANSPONDER WITH FDL-DB-XVR GPS SOURCE .................................................7-8
FIGURE 42: 1201 WIRING DIAGRAM ..............................................................................................................7-1
FIGURE 43: FIGURE1203C WIRING DIAGRAM ................................................................................................7-1
FIGURE 44: OFF-THE-SHELF RS-232 TO USB CONVERTER ...........................................................................8-1
FIGURE 45: SERIAL-TO-WI-FI MPI ................................................................................................................8-1
FIGURE 46: SERIAL-TO-WI-FI AIRCRAFT MODULE..........................................................................................8-2
List of Tables
TABLE 1. MPI PINOUT ................................................................................................................................2-28
TABLE 2. FDL-DB DUAL BAND SERIES INSTALLATION DATA INTERFACES........................................................5-5
TABLE 3. SERIAL PORT INPUT CONFIGURATION SETTINGS..............................................................................5-8