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FEC Mobile Lighting Controller Version 2 (MLC V2)

Type: FEC - HP0722

User Manual – Specification – Diagnostics

Figure 1

MLC

Issue: 1.01 12th April 2018

Powered by eAGLe Light Engines

® Interleader Limited

© Interleader Limited 2018 2 of 30 Printed: 12/04/2018

Document Revision Sheet

Issue Date Changes

1.00 06/09/2017 New Document for MLC V2 – Telit UHF module

1.01 12/04/2018 Updated photos and detailed changes

Figure 2

MLC and MIL-Star®

The eAGLe logo and MIL-Star® name are Registered Trademarks and copyright of Interleader Limited 2017-8


Contents

1 Compliance Statements - USA ....................................................................4

2 Compliance Statement - Europe..................................................................5

3 Overview .....................................................................................................6

4 Architecture .................................................................................................6

5 Capabilities .................................................................................................7

6 System ........................................................................................................8

7 Basic Operation ...........................................................................................9

8 Normal Operation ...................................................................................... 10

9 Default Settings ......................................................................................... 11

10 Battery Run-time ....................................................................................... 12

11 Sunset/Sunrise Switching .......................................................................... 13

12 Battery Capacity ‘Traffic Light’ LED indicators ........................................... 14

13 Charging ................................................................................................... 15

14 MLC Dimensions ....................................................................................... 17

15 MLC and Carry/Charger Case Weight ....................................................... 17

16 Environmental (MLC) ................................................................................ 17

17 Electrical Specification (MLC) .................................................................... 18

18 UHF Radio Modem Specification ............................................................... 19

19 Special Orders .......................................................................................... 20

20 Spare Parts ............................................................................................... 20

21 Support Documentation ............................................................................. 20

22 The Carrying and Charging Case .............................................................. 21

23 UHF Antenna ............................................................................................ 22

24 VHF Antenna and Cables .......................................................................... 23

25 Diagnostics and Fault Finding ................................................................... 25

26 Transportation ........................................................................................... 26

27 Packaging and Labelling ........................................................................... 26

28 Software Updater - MLC ............................................................................ 27

29 Wireless Command Mode ......................................................................... 28

30 Wired Interface .......................................................................................... 29


1 Compliance Statements - USA

FCC Compliance WARNING

Changes or modifications to the transmitter not expressly approved by the manufacturer could void the user's authority to operate this RF device.

FCC Compliance Statement

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:

1. This device may not cause interference, and

2. This device must accept any interference, including interference that may cause undesired operation of the device.

USA-Federal Communications Commission (FCC)

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy. If not installed and used in accordance with the instructions, it may cause harmful interference to radio communications. However, there is no ensured specification that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by tuning the equipment off and on, the user is encouraged to try and correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the distance between the equipment and the receiver.

• Connect the equipment to outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

Any changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.


2 Compliance Statement - Europe

This product has been marked with the CE mark to show it is compliant with the relevant standards.


3 Overview

The Mobile Lighting Controller (MLC) offers VHF control of helipad lights and peripheral equipment either via a UHF transceiver link (to MIL-Star® lights) or using internal relay drivers.

The unit is housed in the same enclosure as the FEC MIL-Star® range of battery helipad lights.

Part Numbers

HP0722 - Standard VHF version

4 Architecture

The MLC is an integral member of the FEC family of lights and controllers enabling either MIL-Star® battery portable lights, Remote Switching Controllers or fixed installation lights to be activated by pilots or ground staff by VHF radio.

The MLC is configured (e.g. setting VHF frequency), managed and may be controlled via a UHF wireless link from a PC or Laptop (not supplied) running FEC’s Systems Management Software.

The MLC is designed to be carried and charged in a MIL-Star® case providing a complete, portable solution in a single case. Charging power can be mains, car, truck or solar.

Figure 3


5 Capabilities

FEC’s Mobile Lighting Controller Version 2 (MLC V2) is an all new, fully digital design that combines ease of installation and use with sophisticated yet simple and secure configuration via a wireless PC Controller Software interface.

The MLC incorporates an advanced microcontroller to provide very flexible and programmable operation, combining proven designs from the FEC Remote Lighting Controller (RLC) and MIL-Star® battery helipad lights.

Key Features

Traditional VHF Pilot Lighting Controller (PLC) configuration

Modern, digital, fully synthesised VHF receiver with programmable:

o 25kHz/8.33kHz frequency setting

o ‘Click’ period (range: 50 – 250mS, Default 100mS)

o Signal strength threshold (range: -10 to -100dBm, Default: -75dBm)

Defined number of presses to activate Channels 1, 2 or 3

o VHF wireless

o Local magnetic key

o PC Controller

Each channel has fully independent programmable time-out (10 seconds to 60 minutes)

3 Channels + 1 Auxiliary transistor switch output to control external power relays

Built in light sensor for optional automatic switching at sunrise and sunset

Built in real-time clock calendar

Stealth mode - provides the facility to turn off the status LEDs after an initial confirmation period (5 seconds).

Housed in MIL-Star® enclosure

o Can be carried in standard Carry/Charger case

o Replaces one of the 8 MIL-Stars

o Compatible charging points for simple lead-free charging

o Whip antenna stored in case lid

Internal 7.5V 2.2Ah Li-Ion battery giving many days operation

Remote test and diagnostics integrated into the unit

Very low power consumption – Approx. 0.5W

Operates from internal battery or 12V DC (ideal for solar and batteries)


6 System

The key system elements of the MLC are shown in figure 4 (top removed for clarity).

The three connectors at the top of the unit are IP65 rated and fitted with dust caps (cap colour may vary).

6.1 Charging & Relay Interface Connector

This 8way Lockable DIN SWUM1 connector can be connected to an external power supply (12 – 30V DC) to power/charge the unit and provides 4 transistor switch outputs (3 channels + 1 auxiliary) to switch external power relays.

6.2 VHF and UHF Antenna Connectors

The VHF and UHF antenna connectors are SMA sockets (reverse gender for USA). The supplied whip antenna is fitted with an SMA plug for direct connection. For fixed installations customers can choose the most appropriate antenna and cable (See later section on antenna).

1 SWUM – Sealed When Un-Mated

Int. UHF Antenna

Wireless LEDs

Serial Number

USB Port

Channel & Aux LEDs

Battery State LEDs

VHF Rx Power & CD LEDs

Battery Isolator (under)

‘Click’ sensor

‘Off’ sensor

‘On’ sensor

Status LED

Charger & Relay Connector

VHF Connector

Charging Power Studs (bottom face)

Charging LEDs

UHF Connector

Figure 4


7 Basic Operation

Basic On, Off and Channel selection of the MLC is achieved by activating magnetic sensors inside the unit using a Magnetic Key Controller (MKC) (supplied).

7.1 Turn MLC On

To turn an MLC on, momentarily bring the MKC in line with the ‘On’ sensor on the unit’s top panel (figure 5).

7.2 Turn MLC Off

To turn an MLC off, momentarily bring the MKC in line with the ‘Off’ sensor on the unit’s top panel (figure 6).

If the unit is already off, bringing the MKC in line with the ‘Off’ sensor, displays the battery status (useful for a quick check without having to turn the unit on)

The Off sensor is also used to put the MLC into software update mode (see later section)

7.3 Select MLC Channel

Channels may be selected without a VHF radio.

With the unit switched on, momentarily bring the MKC in line with the ‘Click’ sensor on the unit’s top panel (figure 7) 3, 5 or 7 times within a 5 second period (just as the pilot would do via VHF).

As each ‘click’ is detected the ‘Status’ LED will light and, after the 5 second period, the selected channel will be activated. (See later section for defaults)

Figure 5

Figure 6

Figure 7


8 Normal Operation

As soon as a VHF signal is detected on frequency the Carrier Detect (CD) LED on the VHF Receiver and the blue Status LED will light for the period that the signal is detected.

During a 5 second period (the international standard for Pilot Controlled Lighting) the system is counting ‘clicks’ from the pilot. The number of clicks (CD) received in the 5 second period is counted and at the end of that period the following occurs:

Clicks Action Comment

1, 2, 4, 6 or 8 or more clicks

No action taken

Return to standby

One click will be detected any time a pilot or ground station on frequency presses their Push-To-Talk (PTT) microphone button.

3 Activate channel 1 If Auxiliary output has been assigned to the selected channel it will also be turned on.

The assigned Group and Program command is transmitted by UHF to activate MIL-Star lights.

After the time-out period the channel/lights are turned off again.

5 Activate channel 2

7 Activate channel 3

If no action is taken then the system will return to standby ready to receive new input.

At any time the pilot can re-activate the same channel or activate a different channel by pressing their PTT again the required number of clicks. The channels requested will be activated and the time-out period will begin counting down again.

The default settings are shown in the next section.


9 Default Settings

The default MLC settings are as below:

9.1 Clicks to Channel Mapping

The following shows the channels that will be selected following the receipt of the correct number of ‘clicks’ in a 5 second period:

Clicks

Channel Program Auxiliary Timeout

Minutes:Seconds

Comment

Default Options Default Options Default Option Default Range

1, 2, 4, 6, 8

None None None None None None None None Input

ignored

3 1 0, 1, 2, 3 1 1 to 5 Off On, Off 15:00 10S-1M (10S

steps)

1-60M (1M steps

Channel 0 is useful for ‘disabling’ a number of

clicks

5 2 0, 1, 2, 3 1 1 to 5 Off On, Off 15:00

7 3 0, 1, 2, 3 1 1 to 5 Off On, Off 15:00

9.2 VHF Radio Settings

The VHF radio is set as follows:

Parameter Default Range Comment

Frequency 122.800 118.00 to 136.98 Configuration uses 8.33kHz channel display convention

Threshold -75dBm -10 to -100dBm Take care using values lower than -85dBm

‘Click’ Period 100mS (1/10second)

50mS to 250mS

9.3 UHF Radio Settings

UHF radio settings are restricted to Original Equipment Manufacturer (OEM) set-up.

9.4 General Settings

Other settings are as below:

Parameter Default Range Comment

Sunset/Normal Switching Normal Sunset/Normal Not implemented this software version

Sunset Light Level 400 Lux 200 – 800 Lux PC Controller Software will force a 100 Lux minimum gap to avoid the unit ‘hunting’

Sunrise Light Level 500 Lux Sunset + 100

Stealth/Normal Mode Normal Stealth/Normal

Running Flash Period 1,000mS TBC Not implemented this software version

Flash Period 100mS TBC

9.5 System Settings

System settings are restricted to OEM set-up.


10 Battery Run-time

10.1 System Off

When ‘Off’, the MLC is in low power ‘sleep’ mode waiting for activation via the magnetic switches. In this condition most of the systems are shut down to conserve power but the microcontroller and sensors are still drawing a small current.

This constant small drain will reduce the battery to half charge in approximately 18 months.

It is essential that the batteries are checked and charged at least every 12 months (see later sections).

10.2 Normal Operation

When the MLC is turned On the systems are fully operating, the VHF receiver is powered on but, to ensure maximum battery run-time the UHF transceiver is off until it is required to switch MIL-Star® lights on or off.

The UHF transceiver will then be switched on for the period of the command and then be powered off again.

In this mode the fully charged run-time is 3 days.

If deployed continuously it is essential that the batteries are checked and charged at least every 2 days (see later sections).

Important Notes

1) The run-time figures above have been obtained from a new unit with a fully charged battery. 2) Battery performance will degrade slowly over time and with charge cycles. 3) This is a guide only and should be validated by the operator prior to use. 4) There will be a variation of run times between MLCs. 5) The MLC will run until the battery is exhausted and then suddenly turn off.


11 Sunset/Sunrise Switching

The MLC can be set to automatically switch the lights on at sunset and off again at sunrise in exactly the same way as individual MIL-Star® lights - except that all lights will be turned on or off together.

When switched to this mode in daylight, the Battery Capacity LEDs will light as normal and MIL-Star® lights will be set off. When the light level becomes less than 400 Lux (the level of light at sunset on a clear day) the defined channel will be turned on. Note that it is the light level that turns the lights on and off, not the time of day. Very overcast conditions causing a dark sky may cause light levels to drop significantly below 400 Lux even though the time is not at sunset. This will cause the MLC to switch lights on (see test results below).

The MLC monitors light level continuously and if the ‘sunrise’ light level of 500 Lux is exceeded, the lights will be turned off again. This may lead to a situation where if the MLC is set to automatic and before sunset a large black cloud causes the lights to be turned on, but then moves away, they may go back off again (as happened in the test below).

The graph below shows the drop in light level from 60 minutes before sunset to sunset. The green bars indicate the actual time the test set of lights came on. MLC results would be similar.

Meteorological conditions at time of test:

Metar from nearby Stansted Airport (EGSS) at 17:20 Zulu, 20th February 2016: Overcast clouds at 1400 feet (recent rain and drizzle). Temp. 11C, Dewpoint 9C, RH 87% 1006hPa.

MIL-Star® - Sunset Switching Test


12 Battery Capacity ‘Traffic Light’ LED indicators

All the time that the unit is switched on the on-board microprocessor monitors the battery voltage to ensure that operation remains within the safe working limits of the battery and to ensure its maximum life.

In all modes, except ‘stealth mode’, when the unit is turned on the battery voltage/capacity is indicated via the three ‘traffic light’ LEDs (Figure 8).

Their status may be interpreted as follows:

LED Status Battery Voltage Meaning

Red flash every 10s <6.00V Battery exhausted – Switch off & Recharge

Flashing Red every 1s 6.00V - 6.25V Battery nearing exhaustion. Switch off & Recharge

Solid Red 6.25V – 6.80V Battery low (<20% remaining).

Solid Orange 6.80V – 7.50V Battery OK (between 20% and 80% capacity)

Solid Green >7.50V Battery Full (>80% capacity)

In practice the green LED will not remain lit for much of the total running time. Most of the running time is spent with the orange LED on. This is normal and to be expected.

Also note that at the transition point between, for example, orange and red, the LEDs may display alternate orange/red at a rate of 1 second per colour. This is normal.

If the MLC has been run continuously until the battery is nearly exhausted and then turned off, the battery voltage may ‘recover’ a little. If turned back on this may show as either the red or orange light coming on briefly but the unit quickly indicating a low battery and shutting down.

Stealth Mode

When the unit is first switched on in Stealth Mode, the Battery Capacity LEDs will light for 5 seconds to indicate the battery capacity. After this initial period, the Battery Capacity LEDs will turn off.

Figure 8


13 Charging

Do NOT Charge from mains with the Case Lid Shut

The MLC is charged in a MIL-Star® carrying case using the integrated mains Power Supply Unit (PSU) or connection to a nominal 12V or 24V DC supply (e.g. car or truck) or directly from a 12V (nominal) PV Solar Panel.

Note that the MLC can be charged in any position but MUST be stored in the position shown as the lid foam is relieved to accommodate the connectors.

Figure 9

Connections:

First ensure that the mains PSU and 12-24V supplies are disconnected.

Ensure that all of the lights and MLC is fitted into the case properly (clear top facing left as Figure 9) with the Power Studs down

Either: Connect the PSU to the mains and switch on, or Connect DC connector to a 12V – 24V DC source

Charging Limits:

The mains PSU is capable of charging 8 lights (or 7 lights + 1 MLC) from exhausted to fully charged in about 3.5 hours (max 4) if the case of the PSU is below 40C (104F). If the case temperature is above this, only 4 lights (3 lights + 1 MLC) can be charged simultaneously.

If the case/PSU temperature is above 50oC (1220F) the PSU must not be used.


If charging 8 lights (or 7 lights + 1 MLC) fully exhausted units from a vehicle’s 12V supply the total load will be 4 Amps. The cable and connector (with 5 Amp fuse fitted) are capable of supporting this load.

Be aware that many vehicle supply sockets may be unable to support this load or that the vehicle’s socket (and then the cable connector) may get hot. This could present a fire hazard. This is particularly likely with an old, used socket. If in doubt, reduce the number of lights being charged simultaneously. Also be aware that this load will reduce the charge available from the vehicle battery.

Battery Status LEDs:

When power is first applied to the MLC, the internal charging circuit first determines the state of the battery, only going to full charge if the battery passes the initial test. If there is a problem with the battery the red Fault LED will be lit. See later section on action to take.

The charger is an intelligent dual-rate charger and, after the initial battery check, will determine exactly how long to charge the battery and at what rate. It will switch off automatically at the end of the main charge. During the initial high charge rate the Charging LED will be lit. This will extinguish once the battery is fully charged.

After Charging:

Once fully charged (and with the charger still connected and switched on) all LEDs will be off. At this point turn off the charger.

Li-Ion batteries have a very low self-discharge current and neither need nor benefit from trickle charging.

A refresh cycle should be performed once every 6 month (more frequently in very hot conditions – see table below) to maintain full charge and best battery condition and life.

Temperature Remaining Capacity After

23oC / 73oF 95% 6 months

45oC / 113oF 80% 3 months

60oC / 140oF 80% 1 month

Disconnection:

To disconnect the charger, switch off the mains supply and remove the power cord or disconnect the DC power cable

Re-store the cable

Good Practice:

Never charge batteries from the mains power supply with the case lid shut

There is no need to leave the charger connected

Always isolate from the mains before connecting/disconnecting

Only charge batteries indoors in dry conditions

Keep batteries away from sources of heat and direct sunlight

Routinely recycle as outlined above

Never charge a battery that appears damaged

Never use a power cord that is damaged in any way

If in doubt – have it checked out

Figure 10


14 MLC Dimensions

MLC

Dimension Value (mm/inches) Comment

Width 84mm / 3.31 inches

Length 98mm / 3.90 inches Including Power Studs and connectors fitted with dust caps

Height 65mm / 2.56 inches Including 6mm base – Standard product

15 MLC and Carry/Charger Case Weight

The weight of the MLC and complete sets (7 MIL-Star® + 1 MLC, case, charger and mains and DC cables) are as follows:

Item Weight (kilograms)

Weight

(US pounds)

Comment

Single Mobile Lighting Controller (6mm Stainless Steel base)

0.73kg 1.61lb 6mm Standard base

Case – Empty (including power supply and mains and DC cables)

4.76kg 10.49lb

System: 7 MIL-Star® + 1 MLC in Case (including power supply and mains and DC cables)

10.60kg 23.37lb Operational system weight

System packed for Shipping TBC TBC As above but with outer foam and shipping box

16 Environmental (MLC)

Degree of protection IP65

MLC Operating temperature: -25oC to +40oC

Charging temperature: -25oC to +40oC

System Storage temperature: -25oC to +50oC

Shock – TBC

Fully ROHC Compliant


17 Electrical Specification (MLC)

Parameter Value

Operating voltage (nominal): 7.5V DC

Absolute voltage range: 6.0V – 8.4V DC

Charger input voltage range: 12.0V – 28.0V DC

Running power consumption: 0.5 watts (maximum with UHF transceiver on)

Sleep power consumption: 0.001 watts (All radios off)

On-board fuses: 2 * 1 Amp (self re-setting type)

Reverse voltage protection: Polarity protected on charger

Surge protection: 600W transient voltage suppressor on external charging connector

VHF antenna connector: SMA Female socket (with dust cap)

UHF antenna connector: SMA Female socket (with dust cap) – NB Reverse gender for USA

Charger & Relay Interface Connector SWUM 8way Locking DIN socket

Battery: Li Ion Battery Pack

Battery Manufacturer: Enix

Battery Type: MGL2807

Nominal Voltage: 7.5V

Nominal Capacity: 2.6Ah

Nominal Energy: 19.5Wh

Battery Protection: Internal self-resetting fuse

Electrical Specification (Carry/Charger Case)

See MIL-Star Manual.


18 UHF Radio Modem Specification

The same Telit UHF Radio Modem is used in MIL-Star, HEMS-Star, RLC, MLC, PLC and KFC and the FEC Systems Management PC Dongle. The Modem has the following specification.

Parameter Value

UK/EU/ROW 868 MHz USA 915MHz

Manufacturer: Telit Telit

Modem type: LE70 - 868 LE70 - 915

Nominal frequency band: 868MHz 915MHz

Frequency (sub)band: 869.525MHz (869.4 - 869.65MHz) 902 – 928MHz (915.375 1st Channel)

Frequency hops/dwell time: N/A 50/350mS

Freq. tolerance @ 20C +/-2.5kHz +/-2.5kHz

Rx filterb 81kHz 81kHz

Deviation: +/-20kHz +/-20kHz

Power output set 100mW (20dBm) 100mW (20dBm)

Receiver sensitivity: Max –110dBm at 38.4kbps Max –110.5dBm at 38.4kbps

Controller range: To 200m subject to antenna & terrain To 200m subject to antenna & terrain

Addressing - module level: Transparent (secure addressing later) Transparent (secure addressing later)

Addressing schema: One to Many One to Many

Addressing – device level: Handled in software Handled in software

Encryption: None (AES 128bit later) None (AES 128bit later)

RF Baud rate: 38.4kbps 38.4kbps

Modem data rate: 19.2kbps 19.2kbps

Modulation: 2GFSK 2GFSK

Operating temperature: -40C to +85C -40C to +85C

Compliance: CE (0682) Compliance for FCC is to 47 CFR part 15.249. FCC ID: R17LE70FH

RF Channel Selection The EU standard sets maximum power transmission limits dependent on frequency, bandwidth and application. A rough guidance applicable to the channels is given below

Channel Number Frequency Centre (MHz) EU Power Allowance

mW/dBm

Notes

0 868.400 25/14

Applicable standard - EN300-220

1 868.900 25/14

2 869.450 100/20

3 869.600 100/20

4 869.800 25/14

All specifications are manufacturer’s data


19 Special Orders

Military Frequency Radios

At additional cost and with a Minimum Order Quantity, units can be supplied with alternative main radios.

Please contact your FEC sales representative to discuss your particular requirements.

Software Features

At additional cost, units can be programmed to perform non-standard functions.

Please contact your FEC sales representative to discuss your particular requirements.

20 Spare Parts

There are no other user serviceable parts.

Items requiring repair need to be returned to FEC

21 Support Documentation

Documentation, including this manual, is contained on the USB memory stick in the case (colour of USB stick will vary).

Also on the USB memory stick are short video clips that demonstrate various aspects of setting up and using the MLC and charger. Updates may also be posted on the FEC website.

Material on the USB Stick:

There are a number of folders on the USB Memory Stick containing:

Application Files Systems Management Software

Battery Data Manufacturers declaration about the battery

Labels Battery shipping labels

Manuals MLC manual (this document)

FEC SMS Manual

MLC Software Software running the MLC

FEC SMS v3.0 Systems Management Software V3

Setup Setup file for Systems Management Software

Figure 11


22 The Carrying and Charging Case

The carrying case can accommodate up to 8 lights (or 7 lights and 1 MLC), has an integrated 100-240V AC Power Supply Unit (PSU) and leads for connection to either the mains supply (for the PSU) or a vehicle nominal 12-24V DC supply. Note that Lights/MLC and PSU may overheat causing fire risk and permanent damage if lid is closed during mains charging.

Figure 12

Always charge lights from the mains with the case lid fully open

MLC MUST be positioned where shown

Documentation on USB Memory

Stick

8 Light Positions (showing optional

black case)

12V – 24V DC Charging

Cable

100 – 240V AC Mains

Charging Cable

Optional Wireless Key

Fob

12V – 24V DC or PV Solar

Connector

100 – 240V Mains AC Connector

Wireless Zulu Dongle and

antenna

Mobile Lighting Controller

(MLC) Position

Magnetic Key Controllers (x2)


23 UHF Antenna

The MLC is supplied with a mag-mount whip antenna which is carried in the lid of the case.

Alternatively, for short range operation or configuration, a stub antenna may be connected

directly to the unit (Figure 13 shows antenna supplied with Telit Dongle):

Figure 13

For semi-permanent installations an optional wall-mounted whip antenna (Figure 14) can be

used:

Figure 14


24 VHF Antenna and Cables

24.1 Standard Mobile Antenna

The MLC is supplied with a simple mag-mount whip antenna (Figure 15): Aviator-2 WSM-225

For installations with good signal strength this all that is required.

If an extension cable is required, the use of RG58 cable is recommended.

24.2 High Gain Antenna

If a higher gain antenna is required. A pole mounted air-band antenna (example Figure 16): Diamond D-777.

This should be specified and installed by an experienced antenna installer.

You are strongly recommended to fit a Static Surge Protector into the down-feed (example: SP-350V).

A typical installation would need:

1) 1 off antenna type e.g. D-777

2) 1 off antenna mounting bracket

3) 1 off Static Surge Protector e.g. type SP-350V

4) 1 off link cable (between antenna and SP-350V) fitted with PL-259 plugs each end

5) 50ohm down-cable (length/type to suit installation – see over)

6) 1 off PL-259 plug to connect to SP-350V, and

7) SMA Plug to connect to the MLC (which will require the use of a reducing adaptor if RG213 cable is used).

Figure 15

Figure 16


24.3 VHF Cable

For a long run you may want to use RG213 cable (this has an outside diameter of 10.3mm).

For a short run you may want to use RG58 cable (this has an outside diameter of 4.99mm).

At the controller end you will need to terminate in an SMA plug (which will require the use of a reducing adaptor if RG213 cable is used).

When installing cable it is not just the diameter of the trunking but two areas are critical and the contractor should be aware:

1) All cables are specified with a Minimum Bending Radius (MBR). Check the data sheet but this is usually a minimum of 10 times the diameter so for the RG213 above is 103mm (4”)

2) Kinking or twisting of the cable must be avoided. If a cable is ‘bent’, even when straightened out again, the internal core will be permanently damaged and cause additional loss and unwanted signal reflections in the cable.

Customers are advised to make sure that:

1) Their contractor is experienced in installing and terminating such cables

2) The cable-ways, ducts, trunking etc. allow for easy bends that exceed the MBR and provide good support

3) The installation work is closely monitored

4) Their installer performs a TDR (Time Domain Reflectometry) test and presents this as part of his certification of installation (the TDR test will both demonstrate that the cable has not been damaged and provide you with a reference document for future audits or checks).

24.4 Installation

Figure 17 gives a suggested general layout for an antenna installation. Your installer will be able to advise on the details specific to your installation.

24.5 Multiple Antenna

Where an RLC is to be installed at a facility with other Airband VHF transmitting devices a separate antenna must be used for the RLC.

To avoid interference or damage to the RLC, the RLC and other device’s antenna should be either:

1) Located some distance apart horizontally (greater than 10 meters), or

2) If located on the same mast, aligned vertically one above the other with an ideal separation of at least 2 meters.

Figure 18 gives the general layout:

Figure 17

Figure 18


25 Diagnostics and Fault Finding

The following are the range of simple tests that an end-user of the MLC can perform – to be carried out in the order given.

Basic Visual Checks – Ensure that:

The unit is properly mounted, secure and appears physically undamaged

There are no signs of overheating or leakage (could indicate a split battery)

Basic Operational Checks – Ensure that:

The magnetic switches operates correctly

If the unit comes on with the Battery Status LEDs showing but then goes out (indicates an exhausted battery)

Check the charge state of the battery

If the unit does not come on at all, go to next step

If unsure of the charge state of the battery, connect to the charger and ensure that the charge cycle is as follows:

1. There may be a brief period before the Green ‘Charging’ LED comes on (charger controller is checking the state of the battery)

2. The Green ‘Charging’ LED comes on an stays on for up to 4 hours (indicates bulk charge cycle)

3. The Green ‘Charging’ LED then goes off (indicates that the charger has entered the trickle charge phase).

If at any time during charging the Red ‘Fault’ LED comes on it indicates a fault has been detected by the charger circuit – most likely with the battery.

1. The first time this happens, disconnect the power and wait 5 minutes before trying again as the fault may clear

2. Repeated display of the Red ‘Fault’ LED indicates a serious fault and the unit should be returned to FEC for rectification

Returning the MLC:

Defective Li-Ion batteries are not permitted to be air transported.

Turn off the unit

Securely wrap the unit in protective foam or similar

Send the unit to FEC for repair – by a permitted carrier (see next section)


26 Transportation

Defective Li-Ion batteries are not permitted to be air transported.

Batteries are subject to special conditions when transported, particularly by air. The relevant ICAO/IATA documents make the following Provision (A67):

IATA-ICAO Provision A67 for the carriage of Batteries

A67 Non-spillable batteries meeting the requirements of Packing Instruction 872 are not subject to these Regulations if, at a temperature of 55ºC (131ºF), the electrolyte will not flow from a ruptured or cracked case. The battery must not contain any free or unabsorbed liquid. Any electrical battery or battery powered device, equipment or vehicle having the potential of dangerous evolution of heat must be prepared for transport so as to prevent:

(a) a short circuit (e.g. in the case of batteries, by the effective insulation of exposed terminals; or in the case of equipment, by disconnection of the battery and protection of exposed terminals); and

(b) unintentional activation

The words “Not Restricted” and the Special Provision number must be included in the description of the substance on the Air Waybill as required by 8.2.6, when an Air Waybill is issued.

The batteries used in the MLC have been qualified by the manufacturer to be compliant with this provision.

27 Packaging and Labelling

Pack the MLC in its original (or appropriate replacement) cardboard box. Attach a warning label to the box.

If an inner and outer box are used, fix labels to both.

A sample label is included on the memory stick for you to enter your contact details onto.

Figure 19


28 Software Updater - MLC

The MLC can be updated with new software by users. Software updates are available as downloads from the FEC website. Two formats are supported; executable (.exe) and self-extracting zip files. If your PC firewall prevents downloading of the .exe file, download and extract the zip file version.

To update the software requires a Windows PC and a USB cable with type ‘A’ plug one end and Micro type ‘B’ the other. The

installer requires neither software nor drivers to be installed on your PC – the standard Windows HID drivers already installed are used.

To update the software:

1) Turn the MLC unit off

2) Open the enclosure as described in earlier section

3) Connect the USB cable to the PC (not yet to MLC )

4) Double click on the update file and a screen similar to that to (Figure 20) will appear

5) Hold the Magnetic Key to the ‘Off’ position – all of the Battery State LEDs will flash – keep holding until they all come on solid. Take away the magnetic key.

6) Insert the micro USB plug into the socket on the MLC (Figure 21)

7) The screen on the PC should now advise that the system is connected and the Install button will have changed from greyed-out to active.

If screen does not confirm it is ready to install, remove the cable from the MLC and repeat from instruction 6

8) Click Install and the software will be automatically uploaded to the MLC

9) A screen (Figure 23) confirms the update in progress

10) When complete:

All of the Battery LEDs will extinguish and the Status LED light

The PC Window will advise it is finished (Figure 24) – click finish and the window will close

11) If Windows asks if the programme installed ok – click yes

12) Disconnect the USB cable

13) Reassemble the controller and turn on in the usual way with the magnetic key.

14) The MLC will now be running the new software

Note that the serial number and wireless type are retained during an upgrade but all other settings revert to factory defaults.

Figure 20

Figure 22

Figure 21

Figure 23

Figure 24


29 Wireless Command Mode

Using the Wireless interface and a PC with FEC Systems Management Software Version 3 (SMS V3) or later it is possible to access the MLC directly and perform a range of control, testing and configuration tasks.

The FEC SMS V3 has a separate manual – Please read carefully before attempting to install or run the software.

Access Rights

There is a hierarchical level of access to the management functions:

User Limited to basic configuration

Manager The basic management level of privilege allowing configuration of a wide range of parameters

FEC As above plus the ability to reset the Manager PIN

OEM As above plus the ability to reset the FEC PIN and perform a number of configuration tasks (e.g. set the unit’s serial number) and diagnostics

Figure 25


30 Wired Interface

The connections for the wired interface are shown right:

Charger Input

Connect +12V to +28V to pin 8 and 0V to pin 6.

Relay Circuits

Ensure that the relay coil voltage rating is the same as the supply (charger) voltage.

Connect each channel as follows:

Channel 1 Pins 8 and 2 Channel 2: Pins 8 and 3 Channel 3 Pins 8 and 4 Auxiliary: Pins 8 and 5

Example: Channel 1 powered from 12V battery with 12V automotive relay:


End of Document

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