ACE Flight Server

User Manual
Document Revision: Release 0.3
» Table of Contents «

1 User Information................................................................................ 1
1.1 About This Document ...................................................................................................................... 1

1.2 Copyright Notice .............................................................................................................................. 1

1.3 Trademark Notice ............................................................................................................................ 1

1.4 Standards ......................................................................................................................................... 1

1.5 Referenced Documents ................................................................................................................... 2

1.6 Warranty........................................................................................................................................... 2

1.7 Commodity Codes ........................................................................................................................... 2

1.8 Important Instructions ...................................................................................................................... 3

1.9 Exclusion of liability notice ............................................................................................................... 3

2 Safety instructions ............................................................................. 4

2.1 Electrostatic Discharge (ESD) ......................................................................................................... 4

2.2 Precautions for Installing the System .............................................................................................. 4

3 Introduction ....................................................................................... 5
3.1 Product Description .......................................................................................................................... 5

3.2 Functional Block Diagram ................................................................................................................ 6

3.3 Equipment Definition ........................................................................................................................ 7

3.4 Major Hardware Components .......................................................................................................... 7

3.5 ComExpress Parameters ................................................................................................................. 8

3.6 Software Components ..................................................................................................................... 8

3.7 Mounting .......................................................................................................................................... 9

3.8 Orderable Part Numbers .................................................................................................................. 9

4 Starting Up ...................................................................................... 10
4.1 Equipment ...................................................................................................................................... 10

4.2 Power Up and Log In ..................................................................................................................... 11

4.2.1 Equipment Setup ............................................................................................................... 11

i
 4.2.2 Power-On ........................................................................................................................... 12

4.3 Sys-Enable Loopback Connector .................................................................................................. 12

4.4 ARINC Loopback Connector.......................................................................................................... 12

4.4.1 Power-On Troubleshooting Matrix ..................................................................................... 13
4.4.2 External Hardware ............................................................................................................. 13

5 Major Hardware Components.......................................................... 14

5.1 Power Supply ................................................................................................................................. 14

5.2 Ethernet Switch .............................................................................................................................. 14

5.2.1 Ethernet switch features .................................................................................................... 14
5.2.2 Ethernet Switch Configuration ........................................................................................... 15
5.2.3 Out-of-Band CLI Access .................................................................................................... 15
5.2.4 Ethernet Service Port ......................................................................................................... 16
5.2.5 In-Band CLI Access ........................................................................................................... 17
5.2.6 Ethernet Switch Firmware .................................................................................................. 18
5.2.7 Ethernet Switch Mapping ................................................................................................... 20

5.3 Signal Interface Board (SIB) .......................................................................................................... 21

5.3.1 Discrete Inputs ................................................................................................................... 21
5.3.2 Discrete Outputs ................................................................................................................ 21
5.3.3 Configuration Signals ......................................................................................................... 21
5.3.4 Remote CPU Reset ........................................................................................................... 21
5.3.5 PSU Status & Voltage Monitoring ...................................................................................... 22
5.3.6 Low Temperature Operation .............................................................................................. 22
5.3.7 GSM Disable/Enable.......................................................................................................... 22

5.4 Removable Solid State Drive ......................................................................................................... 23

5.5 Compact Flash Memory ................................................................................................................. 23

5.6 Analog Audio Outputs .................................................................................................................... 23

5.7 Cellular Modem .............................................................................................................................. 24

5.7.1 Cellar Modem Case Use Example ..................................................................................... 24

5.8 USIM Support ................................................................................................................................ 25

6 System Interfaces ........................................................................... 26

6.1 Front Panel Status Indicator .......................................................................................................... 26

6.2 Connectors ..................................................................................................................................... 26

6.3 Connector Definition J1 (ARINC 600) ............................................................................................ 27

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 6.4 Front Panel Maintenance Connector (J2) Pin Definition ............................................................... 28

6.5 Front Panel RJ-45 Connector (J11) Pin Definition ........................................................................ 29

6.6 Front Panel USIM Card (J30) Pin Definition .................................................................................. 29

6.7 Front View and Dimensions ........................................................................................................... 30

6.8 Top View and Dimensions ............................................................................................................. 30

6.9 Side View and Dimensions ............................................................................................................ 31

6.10 Technical Information..................................................................................................................... 32

6.11 Environmental Requirements ........................................................................................................ 32

7 Wireless-On-Aircraft ........................................................................ 33
7.1 Typical Scenario for WiFi and T-Modem Radio Operation ............................................................ 34

8 Support and Service ........................................................................ 35

8.1 Technical Support .......................................................................................................................... 35

8.2 Returning Defective Merchandise .................................................................................................. 35

9 Appendix A: List of Figures ............................................................. 36

10 Appendix B: List of Tables ............................................................... 37

11 Appendix C: Document Revision History ......................................... 38

iii
1 User Information

1.1 About This Document

This document provides information about products from Kontron and/or its subsidiaries. No warranty of suitability,
purpose, or fitness is implied. While every attempt has been made to ensure that the information in this document is
accurate, the information contained within is supplied “as-is” and is subject to change without notice.

1.2 Copyright Notice

Copyright © 2012 Kontron. All rights reserved. No part of this document may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any language or computer language, in any form or by any means
(electronic, mechanical, photocopying, recording, or otherwise), without the express written permission of Kontron.

1.3 Trademark Notice

This document many include names, company logos and trademarks, which are registered trademarks and, therefore,
proprietary to their respective owners.

1.4 Standards
Standard Description

ARINC 763-3 Network Server System

ARINC 429 ARINC 429 Specification (Mark 33 DITS Specification)

Boeing Standard Cabin Systems Requirement Document FED-STD-595 Colors Used in
D6-36440
Federal Procurement
RTCA/DO-178B Software Considerations in Airborne Systems and Equipment Certification
RTCA/DO-254 Design Assurance Guidance for Airborne Electronic Hardware.
Environmental Conditions and Test Procedures For Airborne Equipment RTCA/DO-178B
RTCA/DO-160F
Software Considerations in Airborne Systems and Equipment
Federal Aviation Regulations for Flammability ISO 9001/2008 International Organization
for Standardization, Quality Management ANSI/IPC-A-620 Acceptability of Electronic
FAR-25.853a Cert
Assemblies ANSI/J-STD-002 Solderability Tests for Component Leads MIL-C-5542
Chemical Conversion Coatings on Aluminum and Aluminum Alloys
ISO 9001 International Organization for Standardization, Quality Management
IPC/WHMA-A-620A Requirements and Acceptance for Cable and Wire Harness Assemblies
IPC-A-610 Acceptability of Electronic Assemblies
ANSI/J-STD-002 Solderability Tests for Component Leads
MIL-C-5542 Chemical Conversion Coatings on Aluminum and Aluminum Alloys
Table 1 - Standards

1
1.5 Referenced Documents
The following table describes the Kontron support documentation:

Document Number Description

73002002 LRU Drawing
73002002-CMM Component Maintenance Manual (CMM)
73002002-FAT Factory Acceptance Test
73002002-FMEA Failure Modes and Effects Analysis (FMEA)
73002002-QTR DO-160 Qualification Test Report
73002002-UM User Manual
Ethernet Switch CLI Reference Manual
Ethernet Switch FASTPATH Configuration Guide

Table 2 - Reference Documents

1.6 Warranty
This Kontron product is warranted against defects in material and workmanship for the warranty period from the date
of shipment. During the warranty period, Kontron will at its discretion decide to repair or replace defective products.

Within the warranty period, the repair of products is free of charge as long as warranty conditions are observed.

The warranty does not apply to defects resulting from improper or inadequate maintenance or handling by the buyer,
unauthorized modification or misuse, operation outside of the product’s environmental specifications or improper
installation or maintenance.

Kontron will not be responsible for any defects or damages to other products not supplied by Kontron that are caused
by a faulty Kontron product.

1.7 Commodity Codes

The following table provides the ECCN and commodity codes for the respective part numbers.

Part Number ECCN HTS

73002002-10x 5A992.A 8517.62.0050

5007120-x EAR99 8544.42.0000

7300100x-00x 5A992.A 8517.62.0050

73001001-001 4A994 8473.30.0002

Table 3 - Commodity Codes

2
1.8 Important Instructions
The following general instructions should always be followed in order to assure the proper operation of the unit, the
safety of operators and the preservation of warranty coverage.

Warning!
All precautions, procedures, and safeguards to prevent damage due to
ESD, and promote the safe handling of electronic components must be
followed.

It is assumed that a competent technician familiar with electro-mechanical assemblies will be performing any testing
or troubleshooting of the unit. For detailed interconnection of power and signal wiring refer to the sections on
Physical I/O and Starting Up.

IMPORTANT: Avoid removing any identification plates, serial numbers or warning labels unless specifically
authorized by the manufacturer.

1.9 Exclusion of liability notice

Exemption from Liability for Accidents

Should the user disregard the instructions (specifically the safety instructions) in this manual and possibly on the
device, Kontron will be exempt from legal liability for accidents.

Limitation of Liability / Warranty Obligations

In the event of damage to the device, which is caused by a failure to observe the instructions (specifically the safety
instructions) in this manual and possibly on the device, Kontron will not be required to honor the warranty, including
during the warranty period, and will be exempt from legal liability for accidents.

3
2 Safety instructions

2.1 Electrostatic Discharge (ESD)

Electronic boards and their components are sensitive to static electricity. Therefore, care must be taken
during all handling operations and inspections of this product, in order to ensure product integrity at all
times. Do not handle this product out of its protective enclosure while it is not used for operational
purposes unless it is otherwise protected.

A sudden electrostatic discharge can destroy sensitive components. Proper packaging and grounding
rules must be observed. Always take the following precautions.

1. Transport boards and cards in electrostatically secure containers or bags.

2. Keep electrostatically sensitive components in their containers, until they arrive at an electrostatically
protected workplace.
3. Only touch electrostatically sensitive components when you are properly earthed.
4. Store electrostatically sensitive components in protective packaging or on anti-static mats.

2.2 Precautions for Installing the System

Important Instructions!

Please follow the corresponding instructions in this manual when installing/mounting the platform.

Please observe all specified dimensions required for mounting included in the drawing with outline
dimensions

When installing the system, there must be at least 40 mm (approximately 1.575") free space around the
cooling fins to prevent the system overheating.

Leave approximately 4.0” (100 mm) of free space to the front of the unit in order to have access to the
front door.

The cooling fins of the chassis must not be obstructed.

The platform must be firmly attached to a clean flat and solid mounting surface. Use proper fastening
materials suitable for the mounting surface. Ensure that the mounting surface type and the used mounting
solution safely support the load of the system and the attached components.

Follow the local/national regulations for grounding. A ground bonding measurement (between chassis
ground and the mounting surface) should be conducted to ensure proper safety and EMI characteristics
are maintained.

The voltage feeds must not be overloaded. Adjust the cabling and the external overcharge protection to
correspond with the electrical data indicated on the type label.

4
3 Introduction

3.1 Product Description

The Server is a network distribution system designed specifically for rugged airborne applications.
The Server Unit includes a high-end dual core processor, a multi-port Gigabit Ethernet Switch, and
removable mass storage for content. The Server can be used as head end component of an In-flight
Entertainment System, data distribution system or other flight communication server applications.
The Server Unit includes aircraft level discrete inputs and outputs to facilitate event notification and
equipment status to and from other aircraft systems, including remote control ON/OFF. The product is
equipped with a power supply unit capable of operating at 115Vac, 360 – 800Hz power with a 200msec
holdup capability for power interruptions. The Server Unit is a completely sealed unit that requires no
active cooling system, and has capabilities for built-in diagnostics reporting.
The Server Unit can communicate with other elements of the aircraft data distribution system over
10/100/1000Base-T Ethernet ports.

Figure 1 - In-flight Entertainment Diagram

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3.2 Functional Block Diagram
The below Figure contains an overview of the functional structure and interfaces

Figure 2 - Functional Block Diagram

6
3.3 Equipment Definition
The Server Unit leverages off of state-of-the-art Commercial Off-the-Shelf (COTS) hardware to establish
a versatile, high performance network Server Unit. Figure 1 depicts the system block diagram of the
Server Unit.

 Standard and Optional features of the Server Unit include:

 Processor: Intel® Core™ i7 2610UE ComExpress form factor

 16GB of DDR3 - 1333 MHz System Memory

 Discrete Inputs/Outputs: 6 Input and 4 Output discretes per ARINC 763

 Aircraft Data Bus: 6 Rx and 3 Tx ARINC 429 channels

 Internal (AC/DC) power with 200msec of interruption holdup capability

 Ethernet Ports:

o Ten Rear 10/100/1000BaseT ports to interface to other airborne components.

o One Rear 10/100BaseT port

o One Front Panel 10/10/1000Base T port

 ARINC 600, 4MCU packaging sealed (no external cooling required)

 Mass Storage: 2x Front removable Solid State Drives (SSD)

 Internal Fixed Solid State Drive (SSD)

 Front Panel Universal Subscriber Interface Module (USIM) Card accessibility

 2 Analog audio outputs to drive PA loudspeakers

 mPCIe card slot for Cellular modem

3.4 Major Hardware Components

The Server Unit major hardware assemblies are:

 ACE Flight Baseboard with ComExpress Processor Module

 Power Supply Unit (PSU) with built-in hold-up (200msec)

 16-port Ethernet Switch

 2x Removable Solid State Drives (ordered separately)

 Signal Interface Board (SIB) CCA

 Status Indicator LED

7
  External Connectors: ARINC 600 connector (J1), Front Panel Maintenance (J13), RJ45 (J11),
and USIM Card (J30)

3.5 ComExpress Parameters

Parameter Description
Processor Number i7-2610UE

# of Cores 2

# of Threads 4

Clock Speed 1.5 GHz (Max Turbo Frequency 2.4GHz)

L2 Cache 4 MB

Memory Type 16 GB DDR3-1333

Chipset Intel Mobile QM67

Ethernet (NIC) Intel 82579LM

Graphics Controller Intel iGFX HD3000

Sound Intel High Definition Audio

Security Features Infineon TPM 1.2 SLB9635TT

Instruction Set 64-bit

Lithography 32 nm
Table 4 - ComExpress Parameters

3.6 Software Components

The ACE Flight Server system is delivered with a pre-configured Linux software load installed on the
internal SSD. This software allows the user to boot and use the system with minimal configuration steps.

The ACE Flight Server software components are as follows:

 Linux OS, 64-bit, based on Ubuntu 12.0.4

 ARINC 429 driver libraries

 Signal Interface Board (SIB) software

 Ethernet Switch Firmware

 Utilities and test code to support system validation

Support for Windows Server (64-bit) 2008 and 2012 is available on request.

8
3.7 Mounting
The Server Unit is designed to mate to standard ARINC 600, 4MCU equipment trays.

3.8 Orderable Part Numbers

Model Number Description

73002002-101 LRU, SERVER, ACE FLIGHT 600 (No internal SSD)

73002002-102 LRU, SERVER, ACE FLIGHT 600 (160GB SSD)

73002002-103 LRU, SERVER, ACE FLIGHT 600 (600GB SSD)

5140550-1 SSD ASSY, REMOVABLE, 160GB

5140550-2 SSD ASSY, REMOVABLE, 600GB

Lab Development Equipment

5155089-3 AIR TRAY & BREAKOUT CABLE ASSY

5007031-2 KIT, EXTERNAL SERVER CABLES

5007348-1 TEST BOX, ACE FLIGHT SERVER

EXTENSION CABLE ASSY, GEN II TO GEN III

5007426-1 (Adds switches for additional discretes for Gen II Test box, only needed if
using a 5006998-1 Test box)
Table 5 - Orderable Part Numbers

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4 Starting Up
The system is ready to use out-of-the-box. Evaluation units come with a complete interface cable set, air
tray and test box as shown in the following table. For production units, trays and cable harness
assemblies can be ordered separately. If you are building your own cable harness, see Section 5 for
signal pin out and mating connector information.

The system is conduction cooled and requires no additional fan assist if operated in the defined
environmental conditions. Note that the unit may get warm to the touch and should be handled with
caution during use.

4.1 Equipment

Label Description Equipment

ACE Flight Server Gen III

1
PN: 73002002-10x

Air Tray, Break-Out Cables

PN: 5155089-3

External Cable Assy Kit (not

2
shown in picture)
PN: 5007031-2

ACE Flight Server Test Box

3
PN: 5007348-1

Removable Solid State Drive

(SSD)
4
PN: 5140550-1 (160GB)
PN: 5140550-2 (600GB)

Table 6 - Equipment

10
4.2 Power Up and Log In
The following setup and power up sequence describes the proper steps for powering up the Server with
the evaluation equipment identified in Section 4.1

Warning!
The specified voltage input range is from 97 to 134 VAC, 47-800Hz, single-
phase power.
DO NOT connect to 220 VAC
The power source must supply a minimum of 64 W.
The power source must be switched off via a 2-pole disconnect device and
must be easily accessible.

4.2.1 Equipment Setup

1. Install the Server into the Server Air Tray Assembly and make sure the Server is fully engaged
into the ARINC mating connector on the tray.

2. Confirm the Server front panel 2x LEDs are OFF

3. Confirm that ALL front panel switches on IFE Server Test Box are in the DOWN position

4. Connect Maintenance Cable Assy to Server Front Panel Maintenance Port

Figure 3 - Test Equipment Diagram

11
4.2.2 Power-On
1. Turn AC Power ON (via Power Switch on 400Hz PSU) to Air Tray Assembly

2. Confirm the Server’s front panel Pwr LED is ON (green color) as AC Power is connected to the
Server Tray Assembly (which routes AC Power to the Server).

3. Confirm that the Sys En (blue color) LED is OFF (since the DC Power is not internally applied
until the Test Box Sys-Enable switch enabled during next steps).

4. On Server Test Box, activate Sys-Enable by flipping switch to UP (ON) position.

Note
If not using the Server Test Box, a Sys-Enable Loopback (PN 5006999-3) is
required to activate Sys-Enable or the Server will not turn on.

5. After about 3 seconds, confirm that Sys En (blue color) LED is now ON (Note: This turn-ON delay
is per expected per design.)

6. On Server Test Box, deactivate Sys-Enable by flipping switch to DOWN (OFF) position.

7. Confirm that the Sys En (blue color) is now OFF and that the Server’s front panel Pwr (green
color) LED is still ON.

4.3 Sys-Enable Loopback Connector

For lab environment, the Sys-Enable needs to be engaged by
either the Test Box or by installing the Sys-Enable loopback
Connector (PN 500699-3) onto the P9 DB-25 cable coming
from the air tray break-out cables. Once installed, and power
is turned on to the unit, the system will come up.

Figure 4 - Sys-Enable Loopback Connector

4.4 ARINC Loopback Connector

For lab environment, it is desirable to test the ARINC signals. The
5007031-2 External Cable Kit comes with the ARINC Loopback
Connector, PN 5005622-8. Install this onto the P10 DB-25 cable
coming from the air tray break-out cables.

Figure 5 - ARINC Loop Back Connector

12
4.4.1 Power-On Troubleshooting Matrix

Symptom Possible Cause Correction

Tray is not plugged in to AC Check J1 cable and verify it is

LED is not illuminated
Power Source plugged in

Check J1 A/C power cable with

LED is not illuminated External power cable is defective
digital multi-meter

LED is illuminated, but there If Test Box is used, enable switch Toggle On the Enable switch on
is no signal output is in the disable position Test Box

Install Sys-Enable Loopback

LED is illuminated, but there If Test Box is NOT used, Sys-
Connector (PN 500699-3) into J2
is no signal output Enable Connector is not installed
Maintenance Port
Table 7 - Power-On Troubleshooting

4.4.2 External Hardware

If using a USB Hub on the USB maintenance port connection, the hub must be externally powered.

13
5 Major Hardware Components

5.1 Power Supply

The Server Unit has an internal PSU that enables the unit to operate from a 97-134 Vac, 47-800Hz,
single-phase power. The PSU is capable of delivering a maximum of 66 Watts via +5 Vdc and +12Vdc
outputs. The PSU provides a minimum holdup capability of 200msec in case of momentary main power
source interruptions (per ARINC 763-3, Section 7.3.3).

The power supply and power sub-systems have the following built-in protection features:

 In-line AC Fuse for short circuit protection due to catastrophic failures

 PSU Over Voltage Protection for protection against outside failures which cause unregulated AC
power IN.

 PSU Over Current Protection for protection against excessive In-Rush currents, and Secondary
DC excessive current demand due to internal catastrophic component failures

 Discrete IO is isolated optically for separation of internal functionality and external varying
conditions.

 Discrete IO is lightning strike protected against failure caused by external lightning strikes which
may present excessive voltage potentials on the exposed IO lines.

 Low Temperature shutoff protection; a circuit which inhibits secondary output power from the
PSU; protecting against excessive current draw for circuits which misbehave at cold
temperatures.

5.2 Ethernet Switch

The Ethernet switch has a total of 16-ports, ten (10/100/1000) ports and a single (10/100) port are
available on the ARINC 600 connector (J1) as standard Quadrax type contacts (one port is a direct
connection to the processor module).

The following documentation is available for more details on the Ethernet Switch interface:

 Ethernet Switch CLI Reference Manual

 Ethernet Switch FASTPATH Configuration Guide

5.2.1 Ethernet switch features

The Ethernet switch has the following features:

 Ports: 16-ports all 10/100/1000Mbps, BaseT

 Interface Ports: Reset, RJ-45 (10/100/1000Mbps), RS232 Console

 Management: CLI, HTTP/HTTPS, SNMP

 MAC Address Table Size: 8K

14
  Network Protocols:

802.3 Ethernet 802.1w Rid Spanning Tree

802.3u Fast Ethernet 802.1s Multiple Spanning Tree Group

802.3ad Gigabit Ethernet 802.1d Spanning Tree

802.1p Priority Tags 802.1Q VLAN

802.3ad Link Aggregation Control 802.1X Authentication Support

 Spanning Tree Support: 802.1d Standard STP; 802.1w Rid STP; 802.1s Multiple STP

 QoS: On all ports

 IPv6 frames

 VLANs: Supports up to 4K VLAN groups

 Link Aggregation: 802.3ad and LACP support

 IGMP Snooping: Supports up to 8K L2 multicast groups; Multicast and broadcast storm control,
as well as flooding control.

5.2.2 Ethernet Switch Configuration

The Ethernet Switch can be monitored via remote SNMP. Please refer to the Ethernet Switch CLI
Reference Manual for a more comprehensive description.

This section provides instructions for initially accessing the CLI of the Ethernet Switch using either in-
band access via an Ethernet port or the out-of-band management interface (serial port) from the front
panel.

The CLI is required for configuring the Ethernet Switch.

5.2.3 Out-of-Band CLI Access

The CLI can be accessed via the front panel serial port via the DB26 Front Maintenance I/O connector
and maintenance cable assembly. Install correctly the cable to the front panel and to the serial port on a
PC. Open a terminal application and set the console port settings as follows:

Name Description

Port COMx (COM port dependent on user connection)

Baud Rate 115200

Data 8 bit

Parity None

Stop 1 bit

Flow None
Table 8 - Serial Port Setting

15
 Log in as admin (no password required by default).

5.2.4 Ethernet Service Port

The Ethernet serviceport has no IP address set by default, it is necessary to assign an IP address
statically or enable DHCP on the serviceport.

Because the required configuration steps are done in the CLI, an initial access using the serial port is
required.

After logging in to the CLI as described in the previous section, enter privileged mode by typing ‘enable’
(no password required by default)

Set the IP address and netmask (example shown)

The Ethernet management interface is available from now on.

Alternatively, DHCP can be set for the serviceport

An IP address will be assigned to the serviceport by a DHCP server.

Save the configuration using the ‘write mem’ command and confirm with ‘y’

16
 To access the CLI via Ethernet serviceport, open a telnet connection to the configured IP address, port
23.

5.2.5 In-Band CLI Access

The Ethernet switch network port (in-band management access) has no IP address set by default, it is
necessary to assign an IP address either statically or by using DHCP to the network port. Access using
the serial port is initially required.

After logging in to the CLI as described in the previous section, enter privileged mode by typing ‘enable’
(no password required by default)

Set IP address, netmask and default gateway (see below example)

The Ethernet management interface is available from now on. Alternatively, DHCP can be set for the
network port.

An IP address will be given to the network port by a DHCP server.

Save the configuration by using the ‘write mem’ command and confirm ‘y’

17
 To access the CLI via the Ethernet in-band networkport, open a telnet connection to the configured IP
address, port 23.

By setting appropriate VLANs, it is possible to separate the management network from the data path.

For additional information on the system configuration, refer to the Ethernet Switch CLI Reference
Manual.

5.2.6 Ethernet Switch Firmware

The system provides for reliable field upgrades. Dual boot images with roll-back capability is supported
along with management via SNMP and Command Line Interface. System access is possible via
TELNET, SSH and serial line.

Two independent system partitions, containing active system and backup system firmware are used to
ensure a reliable and failsafe update.

The active image is stored in flash mtb partitions mtd0-4. The backup system is an exact copy of the
active system and is stored in flash partition mtd5 as a whole. This allows flash recovery from the
redundant system in case that update fails due to power loss or similar errors.

The system update package (res-system-<release>.pkg) contains an image of the bootloader, kernel,
root file-system and config partition as well as MD5 checksum for consistency check.

When performing a firmware update, the software package is loaded form a remote TFTP server. A
software update of the system is done by performing the following steps:

1. Log in to the exec mode of the CLI of the switch board

2. Copy system image into the active image of the flash memory

(Ethernet Fabric) #copy tftp://192.168.50.154/res-system-GA2.00.pkg active

(Ethernet Fabric) #

3. Check availability of valid boot image in active image using the command ‘show bootvar’

(Ethernet Fabric) #show bootvar

Image Descriptions

active : GA2.00

backup : GA2.00

Images currently available on Flash

--------------------------------------------------------------------
unit active backup current-active next-active
--------------------------------------------------------------------
1 1.1.0.0 1.1.0.0 1.1.0.0 1.1.0.0
(Ethernet Fabric) #show board version

Hardware and software revision information

18
 System description : Kontron ESC2404, BETA 1.01, Linux 2.6.27.47-

WR3.0.3bc_standard

Board name: ESC1600

Board serial number: 0400186534

Board part number: 1052-3174

Product serial number: 0400186534

Product part number: 1052-3174

FASTPATH version: 6.4.0.3-FastPath-Ent-esw-xgs4-kex-WL30R-CSxw-6IQH

Broadcom Silicon/Base: BCM56334 rev 18

Processor CPU Type: PPC 405EXr

Processor Clock: 600.000000MHz

Software release information

FASTPATH : BETA 1.01 (20120726183454)

Restart the board

(Ethernet Fabric) #reload

4. In case of problems with booting the system, last working backup image will automatically be
copied to the active image. This procedure restores normal system behavior. Configuration
settings made with active image are lost and should be save by copying the active image to
backup image before.

5. It is recommended to copy the active image to the backup image to have a fully redundant
system

(Ethernet Fabric) #copy active backup

Copying active image to backup image

(Ethernet Fabric) #

19
5.2.7 Ethernet Switch Mapping
The following table provides the port mapping from the L2/L3 Ethernet switch.

GbE Switch Port # ARINC 600 Label (J1) Port Destination

1 J1-B-KK, GG Air Tray P1

2 J1-B-HH, EE Air Tray P2

3 J1-B-LL, JJ Air Tray P3

4 J1-B-DD, AA Air Tray P4

5 J1-B-FF, CC Air Tray P5

6 N/C Front Panel RJ45

7 J1-B-BB Air Tray P15 (10/100BaseT)

8 N/C N/C

9 J1-A-KK, GG Air Tray P6

10 J1-A-HH, EE Air Tray P7

11 J1-A-LL, JJ Air Tray P8

12 J1-A-DD, AA Air Tray P13

13 J1-A-FF,CC Air Tray P14

14 N/C ComExpress Module

15 N/C Baseboard

16 N/C N/C
Table 9 - Ethernet Switch Mapping

20
5.3 Signal Interface Board (SIB)
The Signal Interface Board (SIB) is located internal to the ACE Flight Server adjacent to the ARINC600
connector as previously shown in the system level block diagram. The interface from the Server
processor to the SIB is RS232 serial. The SIB provides input and output functions for the processor.

The primary interfaces and other devices supported on the SIB are:

 Aircraft Discrete I/O

 Front Panel LED control

 Power Supply Unit (PSU) status & voltage monitoring

 Low Temperature Operation

 3G modem enable/disable

5.3.1 Discrete Inputs

The Server Unit provides for six standard ground/open type discrete inputs as defined in ARINC 763-3,
paragraph 2.9.6. These signals are user-defined and can be asserted for a variety of functions including
aircraft key lines (e.g. Weight-on-Wheels, Door Open, Brake Set, etc.). These signals are IN_0, IN_1,
IN_2, IN_3, IN_4, IN_5.

The Server Unit’s discrete input signals are provided on the ARINC 600 connector (J1).

5.3.2 Discrete Outputs

The Server Unit provides four standard ground/open type discrete outputs as defined in ARINC 763-3,
paragraph 2.9.5. These signals are user-defined and can be asserted (active low) for a variety of LRU
status functions. These signals are OUT_0, OUT_1, OUT_2, OUT_3.

The Server Unit’s discrete output signals are provided on the ARINC 600 connector (J1).

5.3.3 Configuration Signals

The SIB accepts three dedicated Configuration Signals (Inputs). These discrete signals provide for
standard ground/open type discrete inputs as defined in ARINC 763-3, paragraph 2.9.6. The logic state
can be read over the computer interface at any time. These signals are CONFIG_0, CONFIG_1,
CONFIG_2.

5.3.4 Remote CPU Reset

The Signal Interface Board (SIB) includes circuitry to affect a remote CPU Reset. This reset sequence is
asserted via a command over the RS232 serial link from the SIB to the control processor on the ACE
Flight baseboard. The remote CPU Reset can be asserted by a momentary ground (Low) on pin C-H1 of
the ARINC 600 Connector

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5.3.5 PSU Status & Voltage Monitoring
The SIB monitors three status signals from the Power Supply Unit (PSU). The three PSU status signals
are described below.

 PSU Fail (DCFAIL_L) is a power supply output, active low TTL level signal indicating that the
power supply has detected an out of tolerance condition with one or more of its power rails.

 AC Fail (ACFAIL_L) is a power supply output, active low TTL level signal indicating that the power
supply has detected the loss of input power. AC Fail is asserted within 10 msec of the loss of the
input power. The PSU continues to operate for at least 200msec after loss of input power.

 PSU Over Temperature (OVERTEMP_L) is a power supply output, active low TTL level signal
used to indicate that the power supply has detected an internal temperature greater than 90ºC.
The PSU will continue to operate until a high temperature limit of 100ºC internal to the PSU is
detected at which point the PSU will shut down.

5.3.6 Low Temperature Operation

The low temperature sensor located within the Server Unit Signal Interface Board (SIB) prevents
operation of the Server Unit when internal temperatures below -20°C (+ 2°C) are detected. This sensor
inhibits the outputs of the PSU until such time as the internal temperature reaches the proper turn on
temperature.

5.3.7 GSM Disable/Enable

The SIB implements the logic to generate an active low TTL signal output used to enable or disable a
GSM Terrestrial Modem. The required logic to determine the enable/disable state of this signal is based
on three input signals from the aircraft (IN_0, IN_1, IN_2) and three qualifier signals (CONFIG_0,
CONFIG_1, CONFIG_2).

The logic determining the GSM Disable output is shown in the following table, where H represents the
open state of the switch associated with the input signal and L represents the closed state of the switch
associated with the input signal.

Parameter 1 2 3 4 5 6 7 8

IN_0 L H L L H H L H

IN_1 L L H L H L H H

IN_2 L L L H L H H H

GSM Disable EN DIS DIS DIS DIS DIS DIS DIS

Table 10 - GSM Disable Truth Table

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5.4 Removable Solid State Drive
The Server Unit includes two removable Solid State Disk (SSD) drives. These drives are easily
assessable via the front access door. The drives are small form factor 2.5” Serial ATA drives that are
housed in independent aluminum canisters. The capacity of the hard drives can be customized based on
customer’s requirements. The standard unit includes two 160GB SSDs A picture of the removable hard
drive is shown.

Figure 6 - Removable Solid State Drive

Note, the SSD supports encryption required for DRM content.

5.5 Compact Flash Memory

The Server includes 8GB of compact flash.

5.6 Analog Audio Outputs

The Server unit supports two audio output channels. This audio interface provides two independent audio
streams to aircraft PA lavatory and cabin loudspeakers. There is one Cirrus Logic CS4207 audio codec
use to provide the primary audio stream interface for the aircraft PA loudspeakers. This device is
connected to the CPU High Definition Audio Bus.

The audio sample rate is specified between 32KHz and 192KHz. These outputs can be enabled through
software control. The analog audio specifications are listed below.

Analog Audio Specification

Number of Channels 2

Line Impedance 600Ω nom

Output Voltage 0.776 Vrms

Frequency Response 50 to 15KHz

Signal to Noise Ratio >60 dB

THD 1% max

Crosstalk <-50dB
Table 11 - Analog Audio Output Specification

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5.7 Cellular Modem
The base configuration is a 3G GSM modem. However a 4G option may be implemented on request.
Contact the factory for further information on the 4G option.

The standard configuration uses the Sierra Wireless MC8795V modem. This modem includes the
following features:

 Frequency Bands: 850/1900/2100 MHz WCDMA

 Air Interface: HSUPA, HSDPA, GSM, GPRS, EDGE

The modem is by default always disabled unless the specific discrete input signals to the server are
asserted. No software intervention is required for the enable/disable of the modem.

There are three discrete input signals (IN0, IN1, IN2) to the server which can be used to determine when
the GSM modem is enabled. There are three “mask” bits (CONFIG0, CONFIG1, CONFIG2) which specify
which of the three discrete inputs are used to enable/disable the modem.

There are two signals which enable the RF transceiver in the wireless modem. A redundant circuit is
utilized to ensure the cellular is properly disable while the aircraft is in flight and any transmission or
reception of data will not interfere with the aircraft avionics. There are two independent programmable
devices which form the basis of this redundant circuit to enable/disable the RF transceiver. The discrete
inputs are used to determine the states of this enable disable function.

5.7.1 Cellar Modem Case Use Example

The requirement is to guarantee that the GSM Modem will always be disabled during flight. Two Discrete
inputs from the aircraft to the Server are used in this example:

 Weight-on-Wheels (WOW) – asserted whenever aircraft is on the ground

 Door Open – asserted whenever aircraft is at gate with door open

WOW is connected to IN0 Discrete input and Door Open is connected to IN1 Discrete input. In this
example IN3 is not connected. To tell the Server to “look at” IN0 and IN1, both CONFIG0 and CONFIG1
pins are grounded on the back side of the ARINC600 Air Tray.

The resulting behavior is as follows:

 The GSM modem is enabled only when both WOW and Door Open are asserted. In other words,
when the aircraft is on the ground and at the gate with door open.

 If either of these discrete inputs are not asserted, then the GSM modem is disabled. In other
words, when the aircraft is in flight or is taxiing to the gate.

Software API calls are provided that can read the state of the Discrete Input signals (IN0, IN1, IN2 plus
spares IN3, IN4, IN5). Also, the two internal signals (redundant) that directly drive the GSM Disable can
be read via software API. A software API call is provided allows that the GSM modem to be disabled if it is
in an enabled state. However, it is not possible to enable the modem from software if it is disabled by the
discrete inputs above. This is necessary for DO-178 Level E compliance.

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5.8 USIM Support
A Universal Subscriber Interface Module (USIM) connector is mounted to the ACE Flight baseboard. A
USIM card with an active account is required for GSM cellular operation.

25
6 System Interfaces
The Server Unit includes system connectors and a visual indicator.

6.1 Front Panel Status Indicator

There are two front panel LEDs. A green LED (LED 1) illuminates when the server is connected to AC
power. This condition indicates that DC power is being applied to the server from the power supply. A
blue LED (LED 2) illuminates only if the internal server electronics is switched on via the power discrete
that is controlled by the SIB.

6.2 Connectors
The following table lists the Server Unit’s external interface connectors.

Ref Des Connector Type Part Number Manufacturer

J1 ARINC 600, Shell Size 2 BKAD2-Q81-40009 F0 ITT Cannon

J11 RJ45 Various Various

J13 DB-26F High Density Various Various

J30 USIM Connector Various Various

Table 12 - Server Connector Definition

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6.3 Connector Definition J1 (ARINC 600)
The following diagram and table provide the signal definitions for the Server Unit J1 ARINC 600.

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6.4 Front Panel Maintenance Connector (J2) Pin Definition

Pin Signal Description

1 RED VGA RED
2 GNR VGA GREEN
3 BLU VGA BLUE
4 5V +5 VOLTS
5 GND DIGITAL GROUND
6 GND DIGITAL GROUND
7 USB- USB DATA -
8 USB+ USB DATA +
9 5V +5 VOLTS
10 RXD_PROC PROCESSOR RS-232 RECEIVE DATA
11 TXD_PROC PROCESSOR RS-232 TRANSMIT DATA
12 DATA VGA DATA
13 HYSNC VGA HORIZONTAL SYNC
14 VSYNC VGA VERTICAL SYNC
15 CLK VGA CLOCK
16 TXD_ENET ETHERNET SWITCH RS-232 TRANSMIT DATA
17 RXD_ENET ETHERNET SWITCH RS-232 RECEIVE DATA
18 GND DIGITAL GND
19-26 NC NO CONNECT
Table 13 - Front Panel Maintenance Connector (J2) Pin Definition

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6.5 Front Panel RJ-45 Connector (J11) Pin Definition
The RJ-45 connector (J11) supports 10/100/1000BaseT communications and is connected to the internal
GbE switch.

Pin Signal Description

1 TRD1+ Bi-Directional Pair 1+
2 TRD1- Bi-Directional Pair 1-
3 TRD2+ Bi-Directional Pair 2+
4 TRD2- Bi-Directional Pair 2-
5 TRD3+ Bi-Directional Pair 3+
6 TRD3- Bi-Directional Pair 3-
7 TRD4+ Bi-Directional Pair 4+
8 TRD4- Bi-Directional Pair 4-
9 LINK- Green Link Status -
10 LINK+ Green Link Status +
11 ACT- Yellow Activity Status -
12 ACT+ Yellow Activity Status +
S1 thru S4 GND Chassis Ground
Table 14 - RJ-45 Front Panel (J11) Pin Definition

6.6 Front Panel USIM Card (J30) Pin Definition

There is a 1.27mm pitch USIM card holder in the front panel. This USIM card holder is of the push-push
style.

Pin Signal Description

1 VCC USIM VCC
2 GND Digital Ground
3 RESET USIM Reset
4 VPP Program Voltage
5 CLOCK Serial Clock
6 I/O Bi-Directional Data
7 SW2 Voltage Reference Input
8 IN No Connect
S1, S2 GND Digital Ground
Table 15 - USIM Card (J30) Pin Definition

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6.7 Front View and Dimensions

Figure 7 - Front View & Dimensions

6.8 Top View and Dimensions

Figure 8 - Top View & Dimensions

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6.9 Side View and Dimensions

Figure 9 - Side View & Dimensions

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6.10 Technical Information

Technical Data
Input Power 115 Volt, 360-800 Hz AC (65W max power dissipation)

In-rush current 5V @ 3.3A; 12V @ 3.4A

Weight 12 Lbs | 5.4 kg

4.88” W x 7.62” H x 12.675” L

Dimensions / Mounting 123.95mm W x 193.55mm H x 321.95mm L
ARINC 600, 4MCU compliant

Reliability (MTBF) < 35,000 hours @ 30ºC

Mean Time to Repair Repair time does not exceed 15 minutes, which entails replacement of the LRU
(MTTR) from its mounting tray.
The server is considered a Line Replacement Unit (LRU) and is repairable only
Maintainability
by Kontron or an authorized repair facility.
Special Tools are not required for the installation, replacement, tuning, or
Special Tools
adjustment of electronic parts.
Table 16 - Technical Data

6.11 Environmental Requirements

Environmental Requirement RTCA/DO-160F D6-36440, Rev D

Temperature - Low:
Ground Survival and Short Term Low Temp. 4.5.1, CAT A1 7.2.1.1
Operating

Operating Low Temperature 4.5.2, CAT A1

Temperature – High:
Ground Survival and Short Term High Temp. 4.5.3, CAT A1
Operating

Operating High Temperature 4.5.4, CAT A1

Altitude 4.6.1, CAT A1 7.2.1.3

Overpressure 4.6.3, CAT A1 7.2.1.3

Operational Shock 7.2, CAT B 7.2.8

7.3.1 (Impulse)
Crash Safety N/A
7.3.2 (Sustained)

Vibration (Random) 8.5.2, CAT A, Curve B 7.2.7

Magnetic Effects 15.0, CAT A

Power Input 16.0, CAT A(WF)H

Emission of Radio Frequency Energy (radiated

21.0, CAT M
and conducted)
Table 17 - Environmental Requirements

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7 Wireless-On-Aircraft
The following provides as information only, additional details and use cases for Wireless-on-Aircraft.

Operation of WiFi network during various phases of aircraft operation is at the discretion of the airline
customer, although may be subject to overview/approval of local aviation authority (FAA, EASA, CAAC,
etc) and local regulatory agencies (FCC & international equivalents).

Operation of the Server Terrestrial Modem radio (cellular) is generally prohibited while the aircraft is in
flight.

As an example, consider a commercial airline flight divided into 4 phases. The Wireless IFE or
Connectivity system usually implements different modes of operation for each of these phases, especially
with regards to operation of the WiFi (CWAP) and Terrestrial Modem (Server) radios.

 On ground, at gate

 On ground, not at gate

 In flight, below 10,000 feet

 In flight, above 10,000 feet

These phases are typically detected by the Airborne Server to support enable/disable of radios:

 WOW (Weight on Wheels) – Discrete input signal that is monitored by the Airborne Server.
Asserted for Phases A & B.

 Door Open – Discrete input signal that is monitored by the Airborne Server. Asserted for Phase A.

 Altitude – ARINC429 data label that is monitored by the Airborne Server. Provides aircraft altitude
value that can be checked against 10,000 foot or other threshold.

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7.1 Typical Scenario for WiFi and T-Modem Radio Operation
Operation of the WiFi network is installation dependent. In some cases, systems allow the CWAP radios
to operate continuously, but in many cases the WiFi is disabled while the aircraft is inflight up to 10,000
feet altitude.

The Terrestrial Modem (T-Modem) in the Server is generally allowed to operate only on the ground. The
enable/disable of the T-Modem is accomplished by monitoring the Discrete Input signals to the Server –
usually WOW and Door Open.

The table below gives an example of an operational scenario during various phases of flight. Note that
this information is provided as an example only and that local or installation dependent requirements may
apply.

Phase of Flight WOW Door Open Altitude WiFi (CWAP) T-Modem (Server)
On ground, at gate TRUE TRUE 0 feet ON or OFF ON
On ground, not at gate TRUE FALSE 0 feet ON or OFF OFF
In flight, below 10K ft FALSE FALSE <10k feet OFF OFF
In flight, above 10K ft FALSE FALSE >10k feet ON OFF
Table 18 - Wifi & Modem Operation Scenario

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8 Support and Service

8.1 Technical Support

Technicians and engineers from Kontron Embedded Modules GmbH and/or its subsidiaries are available
for technical support. We are committed to making our product easy to use and will help you use our
products in your systems.

Please consult our Web site at http://www.kontron.com/support for the latest product documentation,
utilities, and drivers.

8.2 Returning Defective Merchandise

Please use the website to obtain latest information on returning merchandise.

http://us.kontron.com/support/rma-information/

All equipment returned to Kontron must have a Return Material Authorization (RMA) number assigned
exclusively by Kontron. Kontron cannot be held responsible for any loss or damage caused to the
equipment received without an RMA number. The Buyer accepts responsibility for all freight charges for
the return of goods to Kontron's designated facility. Kontron will pay return freight charges back to the
Buyer's location in the event that the equipment is repaired or replaced within the warranty period
stipulated herewith.

To request a Return Material Authorization (RMA) number

Be prepared to supply the unit serial number, reason for return and original ship date
Place call to 800-480-0044 to receive RMA number (toll free in the US and Canada) "OR"
E-mail the information to support@us.kontron.com to receive RMA number
RMA Request Form (found on website)
Return defective material (unless instructed otherwise with issuance of RMA) to:

Contact and Delivery Address

Kontron America
14118 Stowe Dr
Poway, CA 92064
Attn: RMA number

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9 Appendix A: List of Figures

Figure 1 - In-flight Entertainment Diagram....................................................................................................................................5

Figure 2 - Functional Block Diagram ............................................................................................................................................6
Figure 3 - Test Equipment Diagram ........................................................................................................................................... 11
Figure 4 - Sys-Enable Loopback Connector ............................................................................................................................... 12
Figure 5 - ARINC Loop Back Connector..................................................................................................................................... 12
Figure 6 - Removable Solid State Drive ..................................................................................................................................... 23
Figure 7 - Front View & Dimensions ........................................................................................................................................... 30
Figure 8 - Top View & Dimensions ............................................................................................................................................. 30
Figure 9 - Side View & Dimensions ............................................................................................................................................ 31

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10 Appendix B: List of Tables

Table 1 - Standards ......................................................................................................................................................................1

Table 2 - Reference Documents...................................................................................................................................................2
Table 3 - Commodity Codes ......................................................................................................................................................... 2
Table 4 - ComExpress Parameters ..............................................................................................................................................8
Table 5 - Orderable Part Numbers ...............................................................................................................................................9
Table 6 - Equipment ................................................................................................................................................................... 10
Table 7 - Power-On Troubleshooting ......................................................................................................................................... 13
Table 8 - Serial Port Setting ....................................................................................................................................................... 15
Table 9 - Ethernet Switch Mapping ............................................................................................................................................ 20
Table 10 - GSM Disable Truth Table .......................................................................................................................................... 22
Table 11 - Analog Audio Output Specification ............................................................................................................................ 23
Table 12 - Server Connector Definition ...................................................................................................................................... 26
Table 13 - Front Panel Maintenance Connector (J2) Pin Definition ............................................................................................ 28
Table 14 - RJ-45 Front Panel (J11) Pin Definition ...................................................................................................................... 29
Table 15 - USIM Card (J30) Pin Definition ................................................................................................................................. 29
Table 16 - Technical Data .......................................................................................................................................................... 32
Table 17 - Environmental Requirements .................................................................................................................................... 32
Table 18 - Wifi & Modem Operation Scenario ............................................................................................................................ 34

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11 Appendix C: Document Revision History
Revision Date By Changes
0.1 11/10/12 RJM Preliminary Release
0.2 3/30/13 RJM Various Updates
0.3 5/8/13 RJM Various Updates

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