Equipment Installation Manual,

GPS/WAAS 1201 Sensor

EQUIPMENT INSTALLATION MANUAL

for the

FreeFlight Systems

GPS/WAAS 1201 SENSOR

Revision K

FreeFlight Systems
3700 Interstate 35 S
Waco, TX 76706

©Copyright 2009, FreeFlight Systems. All rights reserved.

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Insert latest change pages and destroy superceded pages.

LIST OF EFFECTIVE PAGES

Dates of Original and Change pages are:
Original.............IR......September 23, 2002 Revision ......... J .......... February 21, 2006
Revision ...........A.......September 26, 2002 Revision ......... K ......... June 25, 2009
Revision ...........B.......October 31, 2002
Revision ...........C.......February 3, 2003
Revision ...........D.......March 25, 2003
Revision ...........E.......March 27, 2003
Revision ...........F .......September 18, 2003
Revision ...........G ......February 4, 2004
Revision ...........H.......August 17, 2004
Revision ...........A.......September 26, 2002
Revision ...........B.......October 31, 2002
Revision ...........C.......February 3, 2003
Revision ...........D.......March 25, 2003
Revision ...........E.......March 27, 2003
Revision ...........F .......September 18, 2003
Revision ...........G ......February 4, 2004
Revision ...........H.......August 17, 2004

Page Description Page No. Date

Front Cover - March 27, 2003

Title Page 1 June 25, 2009
List of Effective Pages 2 June 25, 2009
Table of Contents 3 June 25, 2009
Record of Revisions 4 June 25, 2009
Introduction, … 5&6 June 25, 2009
Equipment, … 7 February 4, 2004
Specifications 8&9 June 25, 2009
Operation 10 June 25, 2009
Connector Pin Out 11 June 25, 2009
Appendix A 12 September 18, 2003
A1 13 June 25, 2009
A2 14 June 25, 2009
A3 15 June 25, 2009
A4 16 September 18, 2003
A5 17 February 4, 2004
Warranty 18 September 18, 2003

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Table Of Contents

RECORD OF REVISIONS ...........................................................................................................................4 

INTRODUCTION .........................................................................................................................................5 
DESCRIPTION..............................................................................................................................................5 
PART NUMBERS .........................................................................................................................................5 
REGULATORY COMPLIANCE..................................................................................................................5 
Instructions for Continued Airworthiness, FAR 23.1529, FAR 25.1529, FAR 27.1529, FAR 29.1529...5 
Software .....................................................................................................................................................6 
Hardware ....................................................................................................................................................6 
SUPPLIED EQUIPMENT .............................................................................................................................7 
NOT SUPPLIED............................................................................................................................................7 
SPECIFICATIONS, GPS/WAAS 1201 SENSOR ........................................................................................8 
Certification: ..............................................................................................................................................8 
Physical: .....................................................................................................................................................8 
Electrical: ...................................................................................................................................................8 
Data Input / Output: ...................................................................................................................................8 
SPECIFICATIONS, ANTENNA (P/N 81194)..............................................................................................9 
Certification: ..............................................................................................................................................9 
Physical: .....................................................................................................................................................9 
Electrical: ...................................................................................................................................................9 
OPERATION ...............................................................................................................................................10 
RS232 Input .............................................................................................................................................10 
RS232 Output...........................................................................................................................................10 
CONNECTOR PIN OUT.............................................................................................................................11 
APPENDIX A ..............................................................................................................................................12 
A1 ENVIRONMENTAL; ANTENNA.......................................................................................................13 
A2 ENVIRONMENTAL; SENSOR...........................................................................................................14 
A3 TYPICAL INTERCONNECT ..............................................................................................................15 
A4 OUTLINE DRAWING .........................................................................................................................16 
A5 CONNECTOR BACKSHELL / LATCH ASSEMBLY .......................................................................17 
LIMITED WARRANTY .............................................................................................................................18 
I. HARDWARE ...........................................................................................................................................18 
II. ITEMS NOT COVERED BY WARRANTY .........................................................................................18 
III. LIMITATIONS ON WARRANTY .......................................................................................................18 
LIMITATION OF LIABILITY ...................................................................................................................18 

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RECORD OF REVISIONS

REV DESCRIPTION DATE APPROVED

1 Updated from Draft 4 of 1030-2510-01 020804
2 Removed Salt Spray requirement 020813
3 Correct pin numbers in typical interconnect . 020814
diagram and add ICA.
4 Corrected Environmental tables – add Temp 020907
Variation to antenna, add waterproofness category W
to sensor.
IR FFS Release Per ECN A50171 020923 T. Ellison
A Rev Per ECN A50174 020926 C. Calma
B Rev Per ECN A50176 021031 C. Calma
C Rev Per ECN A50179 030203 T. Ellison
D Rev Per ECN A50190 030325 T. Ellison
E Rev Per ECN A50192 030327 C.K.
F Rev Per ECN A50204 030918 R.R.
G Rev Per ECN F04008 040204 RR 2/4/04
H Rev Per ECN F04060 040817 CW 040817
J Rev Per ECN F06001 060221 DG 060221
K Correct pin numbers in RS232 descriptions and A3 090806 C.Eheim
diagram

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INTRODUCTION
This manual contains installation data and specifications for the FreeFlight Systems, Inc. GPS/WAAS
1201 Sensor, part number 84100-02-XXXX.

DESCRIPTION
The FreeFlight Systems GPS/WAAS 1201 Sensor is a 12-channel parallel tracking GPS/WAAS 1201
Sensor.

• FAA TSO C145a (Beta 1)

• GPS/WAAS 1201 Sensor that determines position and integrity data to an integrated navigation
system.
• Provides integrity through the use of Fault Detection and Exclusion (FDE).
• Supports oceanic and both foreign and domestic en route, terminal, non-precision approach, and
departure operations.

PART NUMBERS
The GPS/WAAS 1201 Sensor is available under the following part number:
84100-02-XXXX GPS/WAAS 1201 Sensor

Note: The last 4 digits of the part number denote software version.

The antenna is available under part number:

81194 Antenna, Aero Antenna

REGULATORY COMPLIANCE
The GPS/WAAS 1201 Sensor is FAA TSO C145a (Beta 1) Approved.

The conditions and tests required for TSO approval of this article are minimum performance standards. It
is the responsibility of those installing this article either on or within a specific type or class of aircraft to
determine that the aircraft installation conditions are within the TSO standards. TSO article must have
separate approval for installation in an aircraft. The article may be installed only if performed under
14 CFR part 43 or the applicable airworthiness requirements.

Instructions for Continued Airworthiness, FAR 23.1529, FAR 25.1529, FAR 27.1529, FAR 29.1529
This statement of compliance with the above FARs is as follows:
Maintenance Requirements-Instructions for Continued Airworthiness
SYSTEM: GWSS
“Modification of an aircraft by this Supplemental Type Certificate obligates the aircraft operator to
include the maintenance information provided by this document in the operator’s Aircraft Maintenance
Manual and the operator’s Aircraft Scheduled Maintenance Program.”

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(1) Maintenance Manual information for the GWSS (system description, removal, installation,
testing, etc.) is contained in FreeFlight Systems Installation Manual, 84143-01.

(2) Line Replaceable Unit (LRU) part numbers and other necessary part numbers contained in the
installation data package should be placed into the aircraft operator’s appropriate airplane
Illustrated Parts Catalog (IPC).

(3) Wiring diagram information contained in this data package should be placed into the aircraft
operator’s appropriate airplane Wiring Diagram Manuals.

(4) Scheduled Maintenance Program tasks to be added to the aircraft operator’s appropriate
airplane maintenance program are as follows:
a. Recommended Periodic Scheduled Servicing Tasks: None Required
b. Recommended Periodic Scheduled Preventative Maintenance Tests/Checks to Determine
System Condition and/or Latent Failures: None Required
c. Recommended Periodic Inspections: None Required
d. Recommended Periodic Structural Inspections: None Required

(5) Unscheduled Maintenance

Unscheduled maintenance may include upgrade of the program software contained in the
GWSS unit.

Software
The software was developed in accordance with RTCA/DO-178B to criticality level C.

Hardware
The GPS/WAAS 1201 Sensor meets the categories of DO-160D indicated in Environmental Qualification
Form found later in this document.

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SUPPLIED EQUIPMENT
Each GPS/WAAS 1201 Sensor is shipped with the following items:

Part Number Description Qty

84100-02-XXXX GWSS GPS/WAAS 1201 Sensor 1
84142-01 Installation Kit, GPS/WAAS 1201 Sensor 1
81194 Hi Speed GPS Antenna 1
84143-01 Equipment Installation Manual 1

Complete installation kits are available under kit part number 84142-01. Individual pieces are available
under the part numbers shown. Contact FreeFlight Systems sales to place orders.

Part Number Description Qty

84142-01 Installation Kit, GPS/WAAS 1201 Sensor
84140 Connector, Receptacle, 25 pin D-Sub 1
84141 Socket, Crimp Style, female 25
84198 Backshell Assy, 25-Pos., 90 deg exit 1
82809 Connector, TNC, Right Angle for RG142 1
84104 (Alt. 84134) Connector, TNC, Straight for RG142 1

NOT SUPPLIED
Coax, RG142 or equivalent.
Insertion loss: Less than 10dB at 1.575 GHz.
DC Resistance: Less than 1 ohm.

Mounting hardware.

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SPECIFICATIONS, GPS/WAAS 1201 SENSOR

Certification:

TSO Compliance................................TSO C145a (Beta 1)

Environmental....................................DO-160D (See appendix)

Physical:
The GPS/WAAS 1201 Sensor attaches to the airframe via six 8-32 screws (not supplied). See the
paragraph titled Outline Drawing for further details.

Height.................................................1.60”
Width..................................................4.13” (Includes mounting flange)
Depth..................................................6.50”
Weight................................................1.2 lb.

Electrical:

Input Voltage .....................................14 or 28 VDC

Input Current......................................0.25 Amp at 28V or 0.5 Amp at 14V

Data Input / Output:

Format ................................................RS232
Baud Rate...........................................19200 Baud, 8 data bits, 1 stop bit and odd parity

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SPECIFICATIONS, ANTENNA (P/N 81194)

Certification:

TSO Compliance ...............................TSO C144

Environmental....................................DO-160C (See appendix)

Physical:

Height.................................................0.60”
Width..................................................3.00”
Length ................................................4.70”
Weight................................................0.375 lb.
Mounting............................................External
Speed Rating ......................................1300kts

Electrical:

Input Voltage .....................................+5 VDC (Supplied by sensor)

Input Current......................................40 mA

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OPERATION

RS232 Input
The sensor receives RS232 input data from the Navigation System on pins J1-20 and J1-23.

Refer to latest revision of the Interface Control Document for input message details.

RS232 Output
The sensor transmits RS232 output data on pins J1-7 and J1-10.

Refer to latest revision of the Interface Control Document for output message details.

NOTE: TX1 (J1-8 & J1-9) and RX1 (J1-21 & J1-22) are reserved for maintenance only.

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CONNECTOR PIN OUT

The Sensor has a 25-pin male connector per MIL-C-24308 available on the front of the unit All
connections except for the GPS antenna are through J1. The mating connector, P1, is described
previously under the section “Equipment Supplied”.

Pin Signal Function

1 unused
2 1 PPS A One Pulse Per Second RS422 A
3 unused
4 unused
5 Shield 1 Ground
6 A+ Primary Power Input 14/28 Vdc
7 TX2 232 RS232 Transmitter # 2
8 TX1 232 RS232 Transmitter # 1
9 TX1 Com Ground for TX1 232
10 TX2 Com Ground for TX2 232
11 unused
12 unused
13 unused
14 unused
15 1 PPS B One Pulse Per Second RS422 B
16 unused
17 unused
18 Shield 2 Ground
19 Power Common 14/28 Vdc Return
20 RX2 232 RS232 Receiver #2
21 RX1 232 RS232 Receiver #1
22 RX1 Com Ground for RX1 232
23 RX2 Com Ground for RX2 232
24 unused
25 unused

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APPENDIX A

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A1 ENVIRONMENTAL; ANTENNA
The 81194 GPS antenna meets the environmental test categories detailed below in accordance with
RTCA/DO-160C, Environmental Conditions and Test Procedures for Airborne Equipment.

NOMENCLATURE: Hi Speed GPS Antenna

PART NO: 81194
MANUFACTURER: Aero Antenna
ADDRESS: 20732 Lassen Street
Chatsworth, CA. 91311
USA

Section Category Remarks

4.0 Temperature and Altitude F2
5.0 Temperature Variation A
6.0 Humidity B
7.0 Operational Shock and Crash Safety 6 g's 11ms
8.0 Vibration C and L
9.0 Explosion Proofness X Not Tested
10.0 Waterproofness S
11.0 Fluids Susceptibility F
12.0 Sand and Dust D
13.0 Fungus Resistance F
14.0 Salt Spray S
15.0 Magnetic Effect X Not Tested
16.0 Power Input X Not Tested
17.0 Voltage Spike X Not Tested
18.0 AF Conducted Susceptibility – Power X Not Tested
Inputs
19.0 Induced Signal Susceptibility X Not Tested
20.0 Radio Frequency Susceptibility X Not Tested
(Radiated and Conducted)
21.0 Emission of Radio Frequency Energy X Not Tested
22.0 Lightning Induced Transient X Not Tested
Susceptibility
23.0 Lightning Direct Effects 2A
24.0 Icing C

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A2 ENVIRONMENTAL; SENSOR
The Sensor meets the environmental test categories detailed below in accordance with
RTCA/DO-160D, Environmental Conditions and Test Procedures for Airborne Equipment.

NOMENCLATURE: GPS/WAAS 1201 Sensor

PART NO: 84100-02-XXXX
MANUFACTURER: FreeFlight Systems, Inc.
ADDRESS: 3700 Interstate 35, Waco, TX 76706
USA

Section Category Remarks

4.0 Temperature and Altitude D2 50,000 Ft Temperature controlled
5.0 Temperature Variation C Partially controlled temperature
6.0 Humidity A Standard Humidity
7.0 Operational Shock and Crash Safety B Fixed wing and helicopter
8.0 Vibration S/U Fixed wing and helicopter (unknown
frequencies)
9.0 Explosion Proofness X Not Tested
10.0 Waterproofness W Falling water, condensation
11.0 Fluids Susceptibility X Not Tested
12.0 Sand and Dust X Not Tested
13.0 Fungus Resistance X Not Tested
14.0 Salt Spray X Not Tested
15.0 Magnetic Effect A 0.3 meter to 1.0 meter
16.0 Power Input B Alternator/rectifier with battery
17.0 Voltage Spike B 56 volts
18.0 AF Conducted Susceptibility – Power B Alternator/rectifier with battery
Inputs
19.0 Induced Signal Susceptibility A Interference free operation desired
20.0 Radio Frequency Susceptibility V 50 volts/meter
(Radiated and Conducted)
21.0 Emission of Radio Frequency Energy B Interference controlled
22.0 Lightning Induced Transient A3E3 600 Volt
Susceptibility
23.0 Lightning Direct Effects X Not Tested
24.0 Icing X Not Tested
25.0 ESD X Not Tested

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A3 TYPICAL INTERCONNECT

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A4 OUTLINE DRAWING

Note: Dimensions are in inches.

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A5 CONNECTOR BACKSHELL / LATCH ASSEMBLY

Assemble the backshell, part number 84198, onto the mating connector as pictured using the hardware
supplied with the backshell. Place jack screws between mating halves of backshell prior to installing
screws and nuts to secure halves together.

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LIMITED WARRANTY
I. HARDWARE
FREEFLIGHT SYSTEMS, LTD. (“FREEFLIGHT”), 3700 Interstate 35 S, Waco, TX 76706, hereby warrants to the first retail purchaser only, that hardware purchased
hereunder will be free from defects in material and workmanship for a period of two (2) years from the date of installation, not to exceed thirty (30) months from the
date of shipment from FREEFLIGHT’s factory. Should defects be found, FREEFLIGHT at its option, will repair or replace the product in which physical defects in
materials or workmanship occur. The foregoing states the sole liability and obligation of FREEFLIGHT arising out of this warranty, and such warranty is subject to the
following CONDITIONS AND LIMITATIONS.
(A) The defect shall occur under normal use and service for which this product was intended. FREEFLIGHT shall not be obligated or liable under this Warranty for
defects which FREEFLIGHT’s examination discloses are due to: (1) tampering, (2) misuse, (3) abuse, (4) neglect, (5) improper storage or maintenance, (6) use in a
manner beyond which such equipment is normally intended to be used, (7) improper repair or poor workmanship by those who are not authorized by FREEFLIGHT
to repair the products or use of defective material by such unauthorized persons, and (8) any other cause except for defects in material or workmanship caused by
FREEFLIGHT.
(B) The warranty card supplied with the product must be completed and returned to FREEFLIGHT within 15 days of installation of the product in order for this
Warranty to become effective.
(C) The product is sold and installed by an authorized dealer. A list of all authorized FREEFLIGHT dealers may be obtained from FREEFLIGHT.
(D) The company must have received a copy of a completed FAA Form 337 covering installation of the product in the purchaser’s aircraft, or equivalent
documentation showing installation of the product by the authorized FREEFLIGHT dealer.
(E) The product shall be returned to FREEFLIGHT via the dealer with transportation charges prepaid. After correction of the defects, the products will be returned to
the purchaser, transportation charges prepaid, except for returns to purchasers in foreign countries, which purchasers shall be responsible for payment of such
charges from the American Port of exit to purchaser’s place of business. The risk of loss or damage to all products in transit shall be assumed by the party initiating
the transportation of such products.

II. ITEMS NOT COVERED BY WARRANTY

EXCEPT FOR THE EXPRESS WARRANTIES GRANTED IN SECTIONS I AND II ABOVE, FREEFLIGHT MAKES NO OTHER WARRANTIES, EXPRESSED OR
IMPLIED, WITH RESPECT TO ITS PRODUCT AND DISCLAIMS THE SAME. FREEFLIGHT MAKES NO EXPRESS OR IMPLIED WARRANTY WITH RESPECT
TO THE DESIGN, ADEQUACY, ACCURACY, RELIABILITY, SAFETY OR CONFORMANCE WITH GOVERNMENT STANDARDS OR REGULATION OF ANY
FLIGHT PROCEDURE PRESCRIBED BY A GOVERNMENT AUTHORITY, INCLUDING, BUT NOT LIMITED TO, ANY EXPRESS OR IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FURTHER, FREEFLIGHT MAKES NO WARRANTY, EXPRESS OR IMPLIED, WITH
RESPECT TO THE ADEQUACY, ACCURACY, RELIABILITY, SAFETY, OR CONFORMANCE WITH GOVERNMENT STANDARDS OR REGULATIONS, OF ANY
INFORMATION CONTAINED IN THE PRODUCT WHICH IS PUBLISHED BY OTHERS OR WHICH FREEFLIGHT OBTAINED FROM OTHERS. FURTHER,
FREEFLIGHT MAKES NO EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO THE COMPLETENESS OF ANY DATA, FLIGHT INFORMATION, OR
FLIGHT PROCEDURE CONTAINED IN ITS PRODUCT. FREEFLIGHT DOES NOT INCLUDE ALL AVAILABLE DATA IN ITS PRODUCT.

III. LIMITATIONS ON WARRANTY

THIS WARRANTY IS LIMITED TO THE ORIGINAL RETAIL PURCHASER, EXCEPT WHERE THE PRODUCT IS USED OR PURCHASED PRIMARILY FOR THE
PURCHASER’S PERSONAL OR FAMILY USE. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING WITHOUT
LIMITATION, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IF ANY, AND SAID IMPLIED WARRANTIES
ARE HEREBY EXPRESSLY EXCLUDED AND DISCLAIMED. WHERE THE PRODUCT IS USED OR PURCHASED PRIMARILY FOR THE PURCHASER’S
PERSONAL OR FAMILY USE, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IF ANY, ARE HEREBY
EXPRESSLY LIMITED TO TWO (2) YEARS FROM THE DATE OF PURCHASE OF THE PRODUCT. SOME STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF AN IMPLIED WARRANTY, OR OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, THEREFORE, THE ABOVE LIMITATIONS CONCERNING
THE EXCLUSION OF IMPLIED WARRANTIES AND LIMITATIONS OF DAMAGES MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC
RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

LIMITATION OF LIABILITY
FREEFLIGHT’S LIABILITY ARISING OUT OF THIS AGREEMENT SHALL NOT EXCEED THE AMOUNTS PAID BY YOU TO OBTAIN THE PRODUCT.
FREEFLIGHT SHALL NOT BE LIABLE FOR SPECIAL, CONSEQUENTIAL, INCIDENTAL OR OTHER TYPES OF DAMAGES, INCLUDING WITHOUT
LIMITATION, LOSS OF USE, LOST PROFITS, AND PERSONAL INJURY. FREEFLIGHT EXPRESSLY EXCLUDES AND DISCLAIMS SUCH DAMAGES
RESULTING FROM OR CAUSED BY, THE USE, OPERATION, FAILURE, MALFUNCTION OR DEFECT OF ANY FREEFLIGHT PRODUCT, WHETHER OR NOT
LIABILITY FOR SUCH DAMAGES IS DUE TO TORT (INCLUDING NEGLIGENCE), CONTRACT, WARRANTY, OR STRICT LIABILITY. THESE LIMITATIONS
WILL APPLY EVEN IF FREEFLIGHT OR AN AUTHORIZED DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGE, AND
NOTWITHSTANDING ANY FAILURE OF ESSENTIAL PURPOSE OF ANY LIMITED REMEDY. YOU ACKNOWLEDGE THAT THE AMOUNT PAID FOR THE
PRODUCT REFLECTS THIS ALLOCATION OF RISK. SOME STATES DO NOT ALLOW THE LIMITATION OR EXCLUSION OF LIABILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
To obtain service under this warranty contact: FreeFlight Systems at (254) 662-0000.

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