FreeFlight 2101 I/O PLUS, Installation And Checkout Manual

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Page 2-1
Revision E
May 31, 2006
FreeFlight 2101 I/O Approach Plus GPS Navigation System
SECTION II - Installation
2.1 GENERAL
This section provides general information for installing the FreeFlight 2101 I/O Approach Plus GPS Navigation System. The
cables will be fabricated by the installation agency to fit these various requirements. This section contains interconnect
diagrams, mounting dimensions and information pertaining to installation.
2.2 UNPACKING AND INSPECTING EQUIPMENT
2.2.1 Physical Inspection
Unpack the equipment carefully and inspect each item for evidence of damage incurred during shipment. If a damage
claim must be filed, save the shipping container and all packing materials to substantiate your claim. The claim should
be properly filed with the transportation company. The shipping container should be saved in the event that storage
or reshipment of the equipment should become necessary.
2.2.2 Electrical Inspection
Each new FreeFlight 2101 I/O Approach Plus is tested and adjusted during final inspection at FreeFlight before
shipment. Normally, unless damage is evident, it is not necessary to do a pre-installation electrical inspection.
2.3 EQUIPMENT INSTALLATION
2.3.1 Cooling Considerations
The greatest single contributor to increased reliability of avionics is to limit the maximum operating temperature of
the individual units, whether DZUS or remote mounted. While circuit designs today consume far less electrical
energy, the watts per cubic inch dissipated within avionics units still remains much the same due to high density
packaging techniques. Consequently, the importance of providing avionics cooling is essential to the life span of the
unit.
While each individual unit may or may not require forced air cooling, the combined heat load of several units operating
in a typical avionics location will significantly degrade the reliability of avionics if provisions for cooling are not
incorporated in the initial installation. Failure to provide cooling will certainly lead to increased avionics maintenance
costs and may void the FreeFlight Navigation Warranty.
Driving Synchro loads generates significant additional heat inside the FreeFlight 2101 I/O Approach Plus. While
forced air cooling is always a good consideration, it is strongly recommended that forced air cooling be installed
whenever Synchro or Roll Steering outputs are used. To facilitate forced air cooling of the FreeFlight 2101 I/O
Approach Plus, an Air Duct attachment kit P/N 81515-00 is available from FreeFlight. This kit, which includes an
Air Duct P/N 81515, Airway Tube P/N 14426, Retainer Ring P/N 16168 and two screws P/N 80448, attaches to the
rear of the unit and has a fitting for a 5/8" ID air hose (see Figure 2-6). Provide at least 2 CFM of air to the air hose.
2.3.2 Harness and Cable Fabrication
The installation agency must supply and fabricate all external cables. The length and routing of external cables must
be carefully studied and planned before proceeding with the installation of the equipment. Avoid sharp bends or
routing the cable too close to aircraft control cables and power sources. When necessary to cross power cables, use
extra-braided shielding and cross at right angles. Take special precaution when transitioning pressure envelopes.
Use cable to connector sealant. Figures 2-1 and 2-2 are the pin-out diagrams and Figure 2-11 is a typical system
interconnection. In addition to the standard aircraft tools, the following special tools are required:
A. Positioner tool P/N M22520/2-06 or equivalent.
B. Crimp tool P/N M22520/2-01 or equivalent.