Mid-Continent Instrument SAM MD302-3 Technical Document

Installation Manual and Operating Instructions
Model MD302-3
Mid-Continent Instruments and Avionics
Mid-Continent Instrument Co., Inc.
dba Mid-Continent Instruments and Avionics
9400 E. 34
th
Street N.
Wichita, KS USA 67226
PH (800) 821-1212 Manual Number 9018233
FX (316) 630-0723 Revision A, December 22, 2014

2 Manual Number 9018233, Revision A
Mid-Continent Instruments and Avionics December 22, 2014
FOREWORD
This manual provides information intended for use by persons who, in accordance with current
regulatory requirements, are qualified to install this equipment. If further information is required,
please contact:
Mid-Continent Instruments and Avionics
Attn: Customer Service Dept.
9400 E. 34th St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
www.mcico.com
We welcome your comments concerning this manual. Although every effort has been made to
keep it free of errors, some may occur. When reporting a specific problem, please describe it
briefly and include the manual part number, the paragraph/figure/table number, and the page
number. Send your comments to:
Mid-Continent Instruments and Avionics
Attn: Customer Service Dept.
9400 E. 34th St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
© Copyright 2014
Mid-Continent Instrument Co., Inc.

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Mid-Continent Instruments and Avionics December 22, 2014
REVISION HISTORY
ECO Rev Date Approved Detail
A 12/22/2014 BMC Production release.

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TABLE OF CONTENTS
SECTION 1GENERAL DESCRIPTION 5
1.1INTRODUCTION .....................................................................................................5
1.2TECHNICAL SPECIFICATIONS................................................................................6
1.2.1ELECTRICAL ATTRIBUTES 6
1.2.2PHYSICAL ATTRIBUTES 6
1.2.3PERFORMANCE LIMITS 6
1.2.4QUALIFICATIONS 6
1.2.5ARINC DATA LABELS 7
SECTION 2INSTALLATION 8
2.1GENERAL INFORMATION.......................................................................................8
2.2PARTS LIST............................................................................................................8
2.3EQUIPMENT LOCATION .........................................................................................9
2.4LIMITATIONS........................................................................................................ 10
2.5MODIFICATIONS .................................................................................................. 11
2.6CABLE HARNESS................................................................................................. 12
2.6.1WIRE GAUGE SELECTION 12
2.6.2CONFIGURATION MODULE 12
2.7PITOT / STATIC CONNECTIONS ........................................................................... 15
2.8INSTALLATION COMPLETION............................................................................... 15
SECTION 3CONFIGURATION 17
3.1CONFIGURATION................................................................................................. 17
SECTION 4CALIBRATION 19
SECTION 5CONFORMANCE 20
5.1INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ........................................... 20
5.1.1PRESSURE SYSTEM AND ALTIMETER VERIFICATION 20
5.1.2SOFTWARE UPDATES 20
5.2ENVIRONMENTAL QUALIFICATION STATEMENT.................................................. 22

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SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The model MD302 series SAM® Standby Attitude Module is a self-contained situational awareness
instrument that provides aircraft attitude, altitude, airspeed and slip indication. The compact and
innovative design of the MD302 is specifically developed for maximum flexibility for installation in retrofit
or modern instrument panels and equipment bays. Its size and AnyWayTM selectable orientation allows it
to be installed almost anywhere and in less space than traditional 2-inch mechanical standby or primary
flight instruments.
Regardless of the aircraft you are flying, the MD302 is a great fit. With a 10 to 32 volt DC input range, the
unit will work with 14 or 28V aircraft electrical buses. The operation and certification of the MD302 make it
well suited for Part 23 and 25 fixed-wing applications as well as Part 27 and 29 rotorcraft.

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1.2 TECHNICAL SPECIFICATIONS
1.2.1 ELECTRICAL ATTRIBUTES
Characteristics:
Input Voltage: 10-32 VDC
Input Power: (nominal) 4 watts (0.12A @ 28VDC)
(maximum) 25 watts max (limited to initial startup)
Lighting Input: n/a
Input Data: ARINC 429 (see Table 1.5)
Output Data: ARINC 429 (see Table 1.5);
discrete valid signal to ground; invalid signal is open (pin 2)
TABLE 1.1
1.2.2 PHYSICAL ATTRIBUTES
Characteristics:
Weight: 1.3 pounds (0.73 kg)
Dimensions:
(without connectors, mates & knob) Bezel: 2.30” x 5.20” x 0.125” (HxWxD)
Chassis: 2.31” x 3.16” x 4.84” (HxWxD)
Mating Connectors: 15-pin D-Sub with Configuration Module, MCIA p/n 9017275
Pneumatic fittings, MCIA p/n 9017642
Mounting: Mount from front; uses (4) #6-32 cap screws
TABLE 1.2
1.2.3 PERFORMANCE LIMITS
Characteristics:
Attitude: Pitch Angle No limits (360°+)
Pitch Rate 300° per second max
Roll Angle No limits (360°+)
Roll Rate 300° per second max
Altitude: Range -1,500 to +55,000 feet (available in meters)
Barometer 28.00 to 31.00 inches of mercury (available in mbar)
Airspeed: Range 20 to 500 knots (available in mph or kph)
TABLE 1.3
1.2.4 QUALIFICATIONS
Specifications:
Certifications: FAA TSO-C2d (Type B), C3e, C4c, C10b, C106, C113a,
C179a
EASA ETSO-C2d, C3d, C4c, C10b, C106, C113, C179a
Environmental Qualification: RTCA DO-160G
(details listed in Section 5.2)
Software Qualification: RTCA DO-178B, Design Assurance Level A
Complex Hardware Qualification: RTCA DO-254, Design Assurance Level A
TABLE 1.4

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1.2.5 ARINC DATA LABELS
All labels are defined as Equipment ID 038 in BNR format.
High and Low speed options for ARINC outputs are configurable.
ARINC 429 Input Speed
Label Description High Low
014 magnetic heading x x
203 altitude (rel 29.92) x x
204 baro altitude x x
320 magnetic heading x x
ARINC 429 Output Speed
Label Description High Low
203 altitude (rel 29.92) x x
204 baro altitude x x
205 mach number x x
206 computed airspeed x x
212 altitude rate x x
215 impact pressure x x
217 static pressure x x
324 pitch attitude x x
325 roll angle x x
326 body pitch rate x
327 body roll rate x
330 body yaw rate x
331 body longitudinal acceleration x
332 body lateral acceleration x
333 body normal acceleration x
336 inertial pitch rate x
337 inertial roll rate x
340 inertial yaw rate x
350 custom label for software version x
364 vertical acceleration x
377 specific equipment id x x
TABLE 1.5

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SECTION 2 INSTALLATION
2.1 GENERAL INFORMATION
IMPORTANT: READ THIS ENTIRE SECTION PRIOR TO STARTING INSTALLATION!
This section contains interconnect diagrams, mounting dimensions and other information pertaining to the
installation of the MD302 SAM Standby Attitude Module. After installation of cabling and before installation
of the equipment, ensure that power is applied only to the pins specified in the interconnect diagram.
2.2 PARTS LIST
When unpacking this equipment, make a visual inspection for evidence of any damage that may have
incurred during shipment. The following parts should be included:
Item Description MCIA Part Number
a. MD302 SAM Standby Attitude Module 6420302-( )
b. Installation Manual – 9018233
c. Connector Kit – 9017646-1
i. Configuration Module 9017275
1. 15-pin D-Sub
2. Backshell
3. Backshell Cover
4. Printed Circuit Board Assembly
5. Screw, Flat, 2-56x1/4 (x2)
6. Screw, 4-40x3/16 (x4)

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2.3 EQUIPMENT LOCATION
The MD302 SAM (-3) Standby Attitude Module is designed to be installed in the instrument panel or
equipment bay of the aircraft. However, within the limitations of the environmental qualifications, other
locations may be acceptable when considered within the context of the specific application and with the
appropriate installation certification.
Clearance for the unit as well as its electrical and pneumatic connections and routing must be allowed. Be
aware of routing cables near other electronics or with other wire bundles that may be susceptible to high
energy flow. Avoid sharp bends in cabling or hoses and routing near aircraft control cables. Also, avoid
proximity and contact with aircraft structures, avionics equipment, heat sources or other obstructions that
could chafe or damage wires or hoses during flight and cause undesirable effects.
FIGURE 2.1
INSTALLATION ORIENTATION OPTIONS
to
p
view
MUST BE INSTALLED IN THE DIRECTION OF FLIGHT
(horizontal shown; also applicable for vertical)
direction
of flight
Panel tilt: -90° to +90°
(horizontal shown; also applicable for vertical)
-90°
+90°
straight and
level flight
side view

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2.4 LIMITATIONS
The conditions and tests for TSO approval of this article are minimum performance standards. Those
installing this article on or in a specific type or class of aircraft must determine that the aircraft installation
conditions are within the TSO standards, specification of the article, and deviations listed below. TSO
articles must have separate approval for installation in an aircraft. The article may be installed only
according to 14 CFR part 43 or the applicable airworthiness requirements.
There are some portions of the approved TSOs which represent outdated requirements or do not apply to
the product. These items are highlighted below and have been submitted to and approved by the FAA as
deviations to the TSO certifications of the product. In the case of FAA TSO and EASA ETSO-C3e, the
MD302 has been approved as an ‘incomplete TSO’. The MD302 meets all TSO requirements for
applicable functions (slip) but does not meet requirements associated with functionality that is not present
in the unit (rate of turn). A note below describes further details regarding the temperature requirements of
FAA TSO-C113a, but does not represent a deviation.
FAA TSO-C2d: Airspeed Instruments
instrument is not labeled with “Airspeed” or “IAS”
FAA TSO-C3e: Turn and Slip Instrument
instrument does not provide rate-of-turn functionality
FAA TSO-C4c: Bank and Pitch Instruments
dielectric strength/insulation resistance does not apply due to electronic components between
chassis and connector pins
FAA TSO-C10b: Altimeter, Pressure Actuated, Sensitive Type
instrument is not labeled with “Altitude” or “ALT”
graduation increments are every 25 feet instead of 20 feet
FAA TSO-C113a: Airborne Multipurpose Electronic Displays
display is operable but marginally usable at -30°C. Display is fully functional at temperatures
higher than -30°C.
Heading Display Function
Does not provide independent heading data, the ARINC data is displayed without
reprocessing; if ARINC data is lost the display will read “---“.

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2.5 MODIFICATIONS
Each model MD302 (part number 6420302-( )) has a nameplate that identifies the manufacturer, part
number, description, certifications and technical specifications of the unit. It also includes the “MOD” or
modification number representing notable changes in the hardware design of the unit. Software revisions
are reflected in the custom ARINC 429 output label 320. The following are descriptions of the current
modification releases of the MD302 Standby Attitude Module.
MOD 0
Modification (MOD) 0 is identified on the nameplate by the lack of marking on the MOD numbers 1
through 9 (i.e. 1-9 are visible).
Mod 0 is the initial release of the MD302 Standby Attitude Module.
MOD 1
Modification (MOD) 1 is identified on the nameplate by the marking/blacking out of MOD number 1 (i.e. 1
is not visible and 2-9 are visible see Figure 2.2 below for example).
Mod 1 of the MD302 Standby Attitude Module contains the following changes from MOD 0:
-Added EMI gasket materials to back plate and battery cover.
-Improved ESD protection.
-Increased design margin of the ARINC RX/TX function.
FIGURE 2.2
NAMEPLATE AND MOD STATUS
MOD 0
MOD 1

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2.6 CABLE HARNESS
Construct the cable harness in accordance with the instructions below including the Connector Pinout of
Table 2.1 and Figure 2.3 and Configuration Module Assembly of Figure 2.4. Installers should follow
industry-accepted practices regarding aircraft wiring and applicable regulatory requirements and
guidance. The instructions for constructing the cable harness as listed within this manual were also used
to construct the harness during environmental and electrical testing. Alterations may invalidate
environmental qualification and/or performance results.
Refer to Section 2.1, Equipment Location for routing precautions.
2.6.1 WIRE GAUGE SELECTION
Wire gauge should be 22 AWG. Use of PTFE, ETFE, TFE, Teflon, or Tefzel insulated
wire is recommended for aircraft use per MIL-DTL-16878 or equivalent. Additionally, for
data signals associated with ARINC 429 inputs and outputs, shielded twisted pair wiring
per M27500 or equivalent is recommended (pin pairs 3 & 8 and 12 & 13).
2.6.2 CONFIGURATION MODULE
The supplied custom configuration module is required for proper installation and
operation of the unit. The functions associated with the 15-pin D-subminiature connector
are identified as follows:
Unit Connector Pin Identification
Pin No. Description Pin No. Description
1 +10-32VDC Input 9 Reserved
2 Valid Signal Out 10 Config Module Clock
3 ARINC Out B 11 Reserved
4 Reserved 12 ARINC In A
5 Config Module Power 13 ARINC In B
6 Power Return / Ground 14 Config Module Data
7 Reserved 15 Config Module Return
8 ARINC Out A
TABLE 2.1
UNIT CONNECTOR PIN IDENTIFICATION
FIGURE 2.3
VIEW FROM REAR OF MATING CONNECTOR

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To assemble the aircraft cable harness and Configuration Module refer to the following instructions
and Figure 2.4:
1) Install a pin/socket as supplied in the Connector Kit using an appropriate crimping tool for each
wire in the aircraft cable harness. Be sure to make the harness long enough to remove the unit
from the front of the panel without stressing the harness (approx. 8” longer than required to
reach the unit connector).
2) Braids from shielded wires should be separated from the wire conductors and pulled back from
the pin/socket termination approximately 2” and gathered together.
a. NOTE: Additional chafe protection, such as heat shrink or nylon wire braid is
recommended over the bundle (not including the shields) to prevent wear when installed
in the cable clamp.
3) Insert the pins of the cable harness into the rear of the 15-pin D-Sub connector (Item 4) per
Table 2.1 and Figure 2.3 using an appropriate pin insertion tool.
CAUTION: The Configuration Module PC Board Assembly contains sensitive electronics that can be
damaged by electrostatic discharge (ESD). Appropriate precautions should be applied prior to
handling this component.
4) Insert the pins of the Configuration Module PC Board Assembly (Item 3) into their corresponding
locations as noted below using an appropriate pin insertion tool.
a. The wires coming from the Configuration Module PC Board Assembly are marked as
follows on the circuit board: TP1, TP2, TP3, TP4.
b. With the D-Sub oriented up (pin locations 1-5 on top), orient the Configuration Module PC
Board Assembly with the electronic parts facing UP prior to pin insertion.
c. Install each pin into the rear of the D-Sub connector as follows:
Board TP1 = config return = D-Sub pin 15
Board TP2 = config data = D-Sub pin 14
Board TP3 = config clock = D-Sub pin 10
Board TP4 = config power = D-Sub pin 5
5) Install the D-Sub Backshell Spring (Item 5) as shown.
6) Place the D-Sub Slide Lock (Item 6) over the D-Sub connector.
7) Install the D-Sub connector with Slide Lock and cable harness attached into the Backshell (Item
1) and secure with (2) screws (Item 8). Verify that the Backshell Spring is between the Slide
Lock and Backshell. Move the Slide Lock back and forth to verify free movement.
8) Route the aircraft wire harness bundle (excluding shield braids) between the two halves of the
Cable Strain Relief Clamp (Item 7). The Clamp should be placed over the chafe protection
installed in Step 2 (if used).
9) Loosely connect the two halves of the Cable Strain Relief Clamp with (2) screws (Item 8).
10) Place the Cable Strain Relief Clamp in the Backshell as shown.
11) Bend the wires of the Configuration Module PC Board Assembly 180 degrees so that the PC
Board has its electrical components facing down as shown. Be careful not to place excess strain
on the solder connections between the wires and the PC Board.
12) Capture the Configuration Module PC Board Assembly into the Backshell by placing the
Backshell Cover (Item 2) on top of the Backshell.
13) Secure the Backshell Cover onto the Backshell using (2) Screws (Item 9).
14) Bundle the exposed shield braids and secure them to either threaded hole on the rear of the
Backshell using a 2-56 screw (Item 10). A wire that is common to aircraft chassis ground shall
also be connected to one of these two holes on the Backshell. Use of a ring terminal (not
included) may be useful.
15) The completed assembly should look as shown. Verify that the Slide Lock operates freely and
that no wires are pinched, nicked, or otherwise damaged.
Verify that power and ground signals are installed appropriately before connecting to the unit.

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FIGURE 2.4
CONFIGURATION MODULE ASSEMBLY
Item Qty Part Number Description
1 1 9017218 Backshell, Size 9
2 1 9017274 Cover, Backshell
3 1 9017184-1 PCB Assy, Config Module
4 1 9016479 Kit, DSub, 15pin HD
5 1 part of 9016479 DSub Backshell Spring Clip
6 1 part of 9016479 DSub Slide Lock, Size 9
7 2 part of 9016479 DSub Backshell Cable Clamp
8 4 90-406-00011 Screw 4-40X3/16 Pan Phil Blk Patch
9 2 90-208-10011 Screw 2-56X1/4 Flat Phil Blk Patch
shield termination

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2.7 PITOT / STATIC CONNECTIONS
The connector kit supplied with the unit contains two (2) pneumatic quick disconnect fittings. These
fittings are specific to the connections on the rear of the unit and required for proper operation.
Aircraft tubing that connects to the unit must be ¼” OD with an approximate 0.17” ID. When determining
tubing length, be sure that it can extend through the cutout in the panel by approximately 8” to allow the
unit to be installed and removed from the front of the panel.
NOTE: It is helpful to identify/label each tube (pitot or static) so that it can be connected to the
correct port on the back of the unit during installation. WARNING: Lock quick disconnect before
connecting to the unit to avoid damaging the O-ring.
2.8 INSTALLATION COMPLETION
Prior to operating the unit in the aircraft, verify the basic operation of the unit and conduct a standard leak
check of the pitot/static system per the aircraft maintenance manual or industry practice.
Configuration information is stored on the configuration module, allowing easy replacement of the MD302.
Because of this, the configuration module must be installed prior to applying power and configuring the
unit (See Section 3.1.)
Within 10 seconds after power is applied, the STAT (status) light should illuminate solid green. This
indicates normal operation. If the STAT light indicates RED, there is an issue preventing normal
operation. See Section 5.1.3 for details regarding operation and troubleshooting.

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FIGURE 2.5
MD302 OUTLINE DRAWING
TABLE 2.2
MD302 UNIT VERSIONS
Unit Versions
Part Number Bezel Battery
6420302-1 Black Yes
6420302-2 Black No
6420302-3 None* No
6420302-4 Gray Yes
6420302-5 Gray No
6420302-6* Black No
* remote mounted unit version. Contact manufacturer for details.

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SECTION 3 CONFIGURATION
IMPORTANT: THE UNIT IS NOT APPROVED FOR FLIGHT UNTIL IT HAS BEEN
CONFIGURED FULLY USING THE INSTRUCTIONS IN THIS SECTION!
This section contains information on how to configure the aircraft specific requirements available with the
MD302 SAM Standby Attitude Module. This includes critical flight parameters that contribute to the safe
and certified operation of the unit and the aircraft.
Only authorized installers and trained personnel should access the Configuration Mode during initial
installation or during maintenance, adjustments and updates.
3.1 CONFIGURATION
Configuration is accomplished through the USB interface similarly to a software update, see Section 5.1.2
for more information regarding software updates.
A specific file must be present in the root drive of the flash drive with the name “mc_conf.dat”. This file
must be formatted as ASCII text with options specified on separate lines as follows:
“mc_conf.dat”:
# MD302 configuration settings file
AIRSPEED_MINIMUM_20_KNOTS
#AIRSPEED_MINIMUM_30_KNOTS
#AIRSPEED_MINIMUM_40_KNOTS
#ARINC_SPEED_LOW
ARINC_SPEED_HIGH
DISPLAY_ORIENTATION_HORIZONTAL
#DISPLAY_ORIENTATION_VERTICAL_RIGHT
#DISPLAY_ORIENTATION_VERTICAL_LEFT
#DISPLAY_ORIENTATION_HORIZONTAL_SWAP
PANEL_TILT={ 0.0 }
PANEL_ROLL={ 0.0 }
Any line beginning with “#” is considered a comment.
Display Orientation is configurable, even though the unit has no display, because it is possible to mount
the (-3) unit vertically.
Panel Tilt is specified in units of degrees from { 90.0 } to { -90.0 }. This compensates for pitch error in the
installation, as seen above in figure X.X. Fractions of a degree may be entered, but will be rounded to
0.5° increments.
Panel Roll is specified in units of degrees from { 5.0 } to { -5.0 }. This compensates for minor roll error in
the installation. Fractions of a degree may be entered, but will be rounded to 0.5° increments.
The defaults are shown in the above example. If any parameters are omitted from the file, the
configuration unit will retain its current setting.
The procedure for updating configuration is to:
1. Power off MD302.
2. Uncover the USB port and insert flash drive containing the configuration file.
3. Power on MD302.
4. The STATUS indicator will blink green while settings are processed.

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5. The RESULT indicator will illuminate green if the settings were accepted.
6. Remove the USB stick while power remains on.
7. The MD302 will reboot and illuminate STATUS green to indicate normal operation with the
new settings.
8. Reinstall USB cover.
If the RESULT indicator is not green following Step 5, the config file was not installed. This could be due
to a misspelled entry or improper syntax.

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SECTION 4 CALIBRATION
Calibration of the altitude and airspeed functions is possible with a single or dual pressure tester. The
procedure is similar to the configuration process in section 3.1 (above).
One or both of the following options may be independently added to the “mc_conf.dat” file to trigger
calibration of airspeed and altitude respectively:
CALIBRATE_AIRSPEED
CALIBRATE_ALTITUDE
If calibrating airspeed, the external tester must be connected to the pitot port of the MD302, with the test
pressure stabilized at 120 knots.
If calibrating altitude, the external tester must be connected to the static port of the MD302, with the test
pressure stabilized at 5,000 feet.
Both calibrations may be done at the same time with a combined P/S tester.
The procedure is:
1. Power off MD302.
2. Uncover the USB port and insert flash drive containing the configuration file.
3. Power on MD302.
4. The STATUS indicator will blink green while calibration is processed.
5. The RESULT indicator will illuminate green if the calibration is successful.
6. Remove the USB stick while power remains on.
7. The MD302 will reboot and illuminate STATUS green to indicate normal operation with the
new calibration.
8. Reinstall USB cover.
If the RESULT indicator is not green following Step 5, the calibration was not completed. This could be
due to a misspelled entry, improper syntax or improper test pressure.
IMPORTANT: AFTER CALIBRATING PRESSURE, THE AIRSPEED AND ALTITUDE
FUNCTIONS MUST BE TESTED FOR THE REQUIRED TOLERANCES ACROSS THE
OPERATING RANGE OF THE AIRCRAFT.

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SECTION 5 CONFORMANCE
5.1 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
5.1.1 PRESSURE SYSTEM AND ALTIMETER VERIFICATION
Per federal regulation 14 CFR 91.411, it is required that each static pressure system and each
altimeter have been tested and inspected within the last twenty-four (24) months.
5.1.2 SOFTWARE UPDATES
Mid-Continent will have, on occasion, the need to update the software of the MD302 to maintain,
improve and/or enhance functionality or performance.
With the MD302’s easy field-upgrade option, the unit does not have to be returned to the factory,
and in some cases, may not have to be removed from the panel.
Software updates are typically communicated to the public via Service Bulletins issued by Mid-
Continent Instruments and Avionics and can be found on the product website, www.flySAM.com.
Below are instructions for updating the unit software.
PREPARATION
1. Prepare software update file.
A. Obtain a USB flash drive from Mid-Continent Instruments and Avionics with the
approved software file loaded,
OR B. Download the approved software file to the root directory of a standard FAT-formatted
USB flash drive from www.flySAM.com/software-updates.
2. Ensure that the unit is powered off.
3. Loosen the screw of the USB access cover on the rear of the unit until the USB port is accessible.
LOAD SOFTWARE
1. Insert flash drive containing the configuration file.
2. Power on MD302.
3. The STATUS indicator will blink green while the update is processed.
4. The RESULT indicator will illuminate green if the update was successful.
5. Remove the USB stick while power remains on.
6. The MD302 will reboot and illuminate STATUS green to indicate normal operation with the
new settings.
7. Reinstall USB cover.
If the RESULT indicator is not green following Step 4, the software update was not completed.
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