Flybox EFC-P User Manual

Electronic Flap Controller

Flybox

®

EFC-P

Revision# 3.1 17/7/2015

For firmware version 1.5

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SECTIONS

MECHANICAL INSTALLATION

TRANSDUCER & ACTUATOR INSTALLATION

ELECTRICAL INSTALLATION

USE OF THE INSTRUMENT

TECHNICAL SPECIFICATIONS

EFC-P - User’s manual

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Introduction

FLYBOX

Thank you for purchasing a Flybox® product. We hope
it fully satisfy you and makes your flights pleasant and
secure.
Developing EFC-P, our intent was to create a compact
and lightweight flap controller, easy to install and use.

SYMBOLS USED IN THE MANUAL

NOTE: Used to highlight important informations.

CAUTION: Used to warn the user and indicate a potentially

hazardous situation or improper use of the product.

WARNING: Used to indicate a dangerous situation that can
cause personal injury or death if the instruction is
disregarded.

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NOTE: Although the EFC-P has been heavily tested to
ensure the maximum safety in every condition, the correct
operation depends also by installation and wiring, that must
be accurately made and verified reading completely this
manual.

NOTE: Keep this manual in the aircraft.
This document must accompany the instrument in the event
of change of ownership.

NOTE: This device is intended for installation onto non type
certified aircraft only, because it has no aviation certifications.
Refer to your local aviation authorities to check if this device
may be installed in your aircraft.

CAUTION: Read entirely this manual before installing the
instrument in your aircraft, and follow the installation and
operating instructions described here.

Important notices & warnings

CAUTION: The pilot must understand the operation of this

instrument prior to flight, and must not allow anyone to use
it without knowing the operation. Don't use this instrument
in flight until you are sure of the correct operating of the same.

CAUTION: When the installation is finished you must do a
test, prior to flight, switching on all the possible source of
electric noise and checking the properly operation of this
instrument.

CAUTION: Using this instrument over the maximum
allowable ranges can cause malfunction or wrong indications.

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Important notices & warnings

WARNING: the EFC-P must be turned off in case of start

with booster. open the corresponding breaker before starting.
warranty shall not apply for damage to the EFC-P for this
reason.

WARNING: The EFC-P is attached directly to the flaps
actuator: the non-respect of the notices above or a damage
to the EFC-P may result in unexpected movements of the
flaps. In this situation you must immediately disable the
EFC-P by turning the switch in the “MANUAL” position (see
chap.4.4 “Use in MANUAL mode”).

WARNING: Responsibility for installation lies entirely with the
installer. Responsibility for operations lies entirely with the
operator.

FLYBOX

IMPORTANT: If you do not agree with the notices above
do not install this instrument in your aircraft, but return
the product for a refund.

Microel s.r.l. reserves the right to change or improve its
products. Information in this document is subject to changes
without notice.

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SECTION 1

Index

1.1

Mechanical installation
Rectangular panel version
2”¼ round panel version

SECTION 2

2.111Transducer installation

2.213Actuator installation

SECTION 3

3.1 Electrical installation

3.2 Wiring diagram for actuator with no
internal limit switches

3.3 Wiring diagram for actuator with
internal limit switches

3.4 Wiring diagram for actuator with
internal limit switches and external
wires

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9

10

15

17

17

18

3.5 Wirings check

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Index

SECTION 4

FLYBOX

4.1

4.2

4.3

4.4

4.5

Panel indicators and commands
Operation instructions
Use in AUTOMATIC mode
Use in MANUAL mode
Troubleshooting and

error code

SECTION 5

5.126Technical specifications

Warranty

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21

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24

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Mechanical installation

SECTION 1

1.1 MECHANICAL INSTALLATION

Ractangular panel version (EFC-P)

Dimensions in millimeters

Panel cut-out

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Mechanical installation

2”1/4 round panel version (EFC57-P)

FLYBOX

Dimensions in millimeters

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2.1 TRANSDUCER INSTALLATION

Transducer installation

SECTION 2

(only if using actuator without
integrated transducer)

The installation consists in the mechanical coupling
between the flaps actuator (motor) and the transducer
(potentiometer) which permits the EFC-P to know the
actual flaps position.

Example of mechanical installations actuator-transducer

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Transducer installation

NOTE:

- The transducer's travel must be at least 10mm more
then the actuator's travel.

- The electrical resistance of the transducer must be
from 1 to 10 Kohm.

- The transducer must be centered over the actuator's
travel so that it isn't possible to exit from the limits, with
consequently damage to the position's transducer.

FLYBOX

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2.2 ACTUATOR INSTALLATION

If the actuator doesn't have any internal limit switches
it's necessary to install them externally.

To avoid the possibility of mechanical and electrical
damage, the actuator travel must match exactly with
the flaps travel: with the actuator completely retracted
(limit switch reached) the flaps must be completely
retracted (or completely extracted for inverse
mechanical coupling); with the actuator completely
extracted the flaps must be completely extracted (or
completely retracted for inverse mechanical coupling).
Adjust your actuator travel if it does not coincide with
the flaps travel, for example using an arm/lever with an
appropriate length.

Actuator installation

If the condition above indicated is not satisfied the
actuator is not protected against possible overtravel
during flap extension and retraction, therefore a pilot
that drive the flaps manually (for example using
“Manual” mode of the EFC-P) can cause mechanical
damage if he don't stop exactly when the flaps have
reached the up and down positions.

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Actuator installation

Correct installation: actuator travel exactly match flaps
travel.

FLYBOX

IMPORTANT NOTES ON USING ACTUATORS WITH
INTEGRATED TRANSDUCER:

- The electrical resistance of the transducer must be from 1
to 10 Kohm.

- Choose a model that use the maximum electrical
resistance range. For example if you choose an actuator
with 10 Kohm transducer, verify that the stroke that you are
going to use provide at least a variation of half the
transducer's resistance, i.e. 5 Kohm.

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Electrical installation

SECTION 3

3.1 ELECTRICAL INSTALLATION

In the backpanel there is a 10-poles plug connector (model:
MOLEX Mini-Fit JR.); the corresponding socket connector is
delivered with your EFC-P.

Backpanel plug

Socket view (from wire'insertion side)

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Electrical installation

Connector pinout:

1 – Motor out (-)
2 – Power input (+12V)
3 - Positive voltage (+5V) for the position's transducer
4 – Position's transducer signal
5 – Ground for the position's transducer
6 – Motor out (+)
7 – Power input (GND)
8 – “DOWN” limit switch
9 – Limit switches common connection
10 – “UP” limit switch

NOTE: Insert a breaker to the power lead (+12V);
choose a correct amperage depending on the actuator
installed.

FLYBOX

Use avionic cable.

It’s recommendend to use shielded cable (2
poles+shield) for the motor output (pin#1 & 6),
connecting the shield of the cable to ground on the
EFC-P side and leaves disconnected the shield on the
actuator side.

WARNING: Voltage peaks higher than 15 Volt on the
supply line can damage the device.

WARNING: The EFC-P must be turned off in case of
start with booster. Open the corresponding breaker
before starting.

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Electrical installation

3.2 WIRING DIAGRAM FOR ACTUATOR WITH

NO INTERNAL LIMIT SWITCHES

If the actuator used has no internal limit switches you must
install them externally and follow the wiring diagram below.
The UP and DOWN switches must be normally closed; diodes
max current must be at least 3 Ampere.

Pay attention to the UP and DOWN limit switches mechanical
and electrical installation, because a wrong connection can
prevent the EFC-P from turn off the actuator before the
mechanical stop, with possible damage to the actuator itself.

Wiring diagram for actuator with no internal limit switches

3.3 WIRING DIAGRAM FOR ACTUATOR WITH

INTERNAL LIMIT SWITCHES

If the actuator used has integrated limit switches and wiring
(no external wires) use the wiring diagram above, connecting
pin #1 and #6 of the EFC-P connector directly to the actuator.

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Electrical installation

FLYBOX

3.4 WIRING DIAGRAM FOR ACTUATOR WITH

INTERNAL LIMIT SWITCHES AND
EXTERNAL WIRES

If the actuator used has 3 wires for the limit switches
connection, probably one wire is the common contact for the
limit switches, so the wiring diagram to the EFC-P is the
following:

Wiring diagram for actuator with internal limit switches and external wires.
Note that the common contact of the limit switches is connected to pin
#9.

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Electrical installation

3.5 WIRINGS CHECK

FIRST CHECK:

When finished all the wirings turn the Auto/Manual switch in
Manual position and check the flaps movement with the
UP/DOWN switch: press in “DOWN” position and check that
the flaps go down, press in “UP” position and check that the
flaps go up. If directions are reversed swap the two actuators
wire (pin 1 and 6 on the EFC-P connector).

SECOND CHECK:

The wiring between the transducer and the EFC-P connector
(pins 3-5) depends on the actuator-transducer mechanical
coupling (i.e. flaps down-->transducer's shaft extracted or
flaps down-->transducer's shaft retracted).
To check if the wirings are ok measure the voltage between
ground (pin#7) and pin #4 of the EFC-P connector:
with the flaps completely down the voltage must be to its
maximum value, with the flaps completely up the voltage
must be to its minimum. If this doesn't occur, or if the EFC-P
does not work correctly, swap the two wires on pins #3 and
#5 of the EFC-P connector.

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Panel indicators & commands

FLYBOX

SECTION 4

4.1 PANEL INDICATORS AND COMMANDS

LED 1

LED 2

A/M switch

(Auto/Manual)

LED 3

LED 4

NOTE: The Auto/Manual switch has a safety lock to
avoid accidental operation: it must first pulled on the
outside and then moved to the desired position.

U/D switch

(Up/Down)

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Operation instructions

4.2 OPERATION INSTRUCTIONS

The EFC-P can work in two modes: Automatic or Manual.
For normal operations use the “Automatic” mode; the
“Manual” mode must be used only in case of emergency or
failure of the EFC-P.

NOTE: Before using the device for the first time you must

program the four position that the EFC-P store in memory
and use in Automatic mode. Follow this steps to perform the
programming:

● With the device powered off turn the A/M switch in the
“Automatic” position, then press and hold the U/D switch
in the “UP” position..

● Power on the EFC-P and wait 10 seconds until the LED1
and the LED4 come on steady.

● Release the U/D switch (LED1 and LED4 start flashing).
NOTE: The EFC-P doesn't enter in the programming
mode if a limit switch is open (UP or DOWN limit switch);
if this occour you must turn in “Manual” mode and move
the flaps until the limit switch will de-activate, then repeat
the programming sequence from the beginning.

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Operation instructions

● Make this sequence using the U/D switch: 2 click in the
UP position, 2 click in the DOWN position and 1 click in
UP; if the sequence is correct the EFC-P enters in
programming mode and the LED2/LED3 briefly flash.

● Now the first led is flashing indicating that you can adjust
the flaps in the desired position (using the U/D switch).
To store the position, briefly move the A/M switch in
“Manual” and then return in “Automatic”.

● Now the second led is flashing and you can adjust and
then store the second position in the same way explained
in the previous step (U/D switch to adjust then A/M
switch to store the position). Repeat again the step for
the third and fourth position.The EFC-P will automatically
exit from the programming mode and become operative
once the last position is correctly stored in memory.

FLYBOX

NOTE: If the EFC-P is powered on the first time without enter

in the programming mode the four LED will simultaneously
flash.

The positions remains stored in memory also without
power supply.

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Use in AUTOMATIC mode

4.3 USE IN AUTOMATIC MODE

In AUTOMATIC mode you can move the flaps choosing one
of the four stored position; the maximum travel of the motor
is defined by the two limit switches UP and DOWN.

The LEDs show the status of the flaps:

LED on: indicate the current position of the flaps
LED flashing: indicate the position that the flaps are reaching

-EXAMPLE OF USE-

The flaps are in the first position (LED1 on, all other LEDs
off):
to move the flaps in the third position press two times the U/D
switch in the DOWN position; the flaps start moving and the
third LED is flashing, indicating the position that the flaps are
reaching.
When the flaps reaches the second position the first LED turn
off while the second turn on; when they reaches the third
position the second LED turn off and the third turn on. The
flaps have reached the selected position and the EFC-P
return to steady state, waiting for another command.

Pressing the U/D switch in the UP position for more than 1
second move automatically the flaps to the first position
(regardless of the current position).

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Use in MANUAL mode

FLYBOX

4.4 USE IN MANUAL MODE

In this mode the flaps position are not fixed between the four
programmed positions but the movement are continuous;
however it's recommended to use the MANUAL mode only
in case of device's electronic failure, because this mode
bypass the internal electronic circuits and connect directly
the motor to the U/D switch.

To control the flaps simply use the U/D switch: press and hold
in a position (UP or DOWN) and release when the motor have
reached the desired position.

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Troubleshooting and error code

4.5 TROUBLESHOOTING AND ERROR CODE

● All the four LEDs flashing: no positions' programming

have been made (see chap. 4.2)

● LED1 and LED2 flashing: it means that the EFC-P try

to move the motor but there is no feedback from the
transducer: can be a wrong connections on the motor's
wiring or on the transducer's wiring.
To exit from this condition you must turn off the device
and remove the cause of failure.

● LED1 and LED3 flashing: it means that the connection

motor/transducer are not correct; maybe the motor's
wire reversal or a wrong tranducer wiring.
To exit from this condition you must turn off the device
and remove the cause of failure.

● LED2 and LED4 flashing: it means that the EFC-P has

detected an over-current condition. Check that wirings
of the actuator motor have no short circuits or check
that the actuator is working correctly.

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Technical specifications

FLYBOX

SECTION 5

5.1 TECHNICAL SPECIFICATIONS

● Frontpanel dimensions:

61.8 x 71.8 mm (rectangular panel version).

60.0 x 60.0 mm (2”1/4 round panel version).

● Depth:

46 mm (rectangular panel version).

52 mm (2”1/4 round panel version).

● Weight: 125 g.

● Power requirements: 12 ~ 20 V=, 80 mA.

● Maximum current supplied to the motor: 7 Ampere.

● Operating temperature range: -20 ~ +70 °C.

● Relative humidity: 10% ~ 90% without condensation.

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WARRANTY:

This product is warranted to be free from defects for a
period of 12 months from the user invoice date.

The warranty only cover the manufacture's defects; shall
not apply to product that has been improper installed,
misused or incorrect maintenance, repaired or altered
by non-qualified person.

Date

06/2011 2.8 First release
11/2014 3.0 Layout update
7/2015 3.1 Updated chap.4.2

WARNING: All photos, data, drawings, instruments layouts, technical solutions and
data representation you find in this document or watching at FLYBOX® instruments
working and/or you can access by means of any other media, including web sites,
are sole property of MICROEL s.r.l., cannot be copied or imitate without a written
permission of MICROEL s.r.l. itself and are protected by law, even by means of
extended international copyright and/or specific patents deposited. Any infringement
of this statement and of MICROEL s.r.l. intellectual property will be prosecuted.

Revision Description

©2015 Microel s.r.l. – all rights reserved.

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MICROEL s.r.l.

Via Mortara 192-194

27038 Robbio (PV) - ITALY

Tel [phone] - Fax [phone]

www.flyboxavionics.it