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Portable Ground Control Station

A Universal Off-the Shelf Solution

User manual V 1.1
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Contents

1 System overview............................................................................................................................................................. 3

2 Specifications.................................................................................................................................................................. 5

3 System Description ......................................................................................................................................................... 6

3.1 Power distribution system...................................................................................................................................... 6

3.2 The modular electronics compartment.................................................................................................................. 6

3.3 Connections ............................................................................................................................................................ 9

3.4 Switch description.................................................................................................................................................12

4 GCSsetup.......................................................................................................................................................................13

4.1 Electronics installation in MEC..............................................................................................................................13

4.2 Battery installation................................................................................................................................................14

4.3 Battery charger .....................................................................................................................................................15

4.4 External power connection...................................................................................................................................15

4.5 Toughbook installation .........................................................................................................................................16

4.6 Foldable stand.......................................................................................................................................................17

5 Operation......................................................................................................................................................................18

5.1 Power Status Display.............................................................................................................................................18

5.2 VGA setup .............................................................................................................................................................19

5.3 17” LCD display setup............................................................................................................................................20

6 Troubleshooting............................................................................................................................................................22

7 Contacts ........................................................................................................................................................................23

8 User manual version history .........................................................................................................................................23

9 References ....................................................................................................................................................................23
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1 System overview

Thank you for purchasing UAV Factory’s portable ground control station. UAV Factory’s off-the-shelf portable Ground 

Control Station (GCS) is a flexible and universal solution for controlling unmanned vehicles and payloads. The general 

overview of the GCS is given in Figure 1.

The GCS can be configured to control unmanned aircraft vehicles (UAV), ground robots, bomb disposal robots, remotely 

operated vehicles (ROV) and other robotic devices. The GCS can also be configured to control and monitor other 

measurement and sensing equipment.

Based on Panasonic’s field proven CF-31 Toughbook(1), the GCS has additional 17’’ sunlight readable touch screen

display, advanced power distribution system with hot-swappable dual batteries and status monitoring features. The GCS 

is housed in a military grade rugged, lightweight case which makes it ideal for use in harsh environments.
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Figure 1 Portable ground control station system overview

*Panasonic Toughbook CF-31 is not included with the GCS and 

needs to be purchased separately from your local supplier
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2 Specifications

Mechanical Specifications 

Dimensions 1000 x 420 x 170 mm

Weight (excl. Panasonic Toughbook CF-31) 18.9 kg

Environmental protection IP66 when closed

Operating temperature -20 to +70 °C (if equipped with wide temperature display)

Electronics compartment dimensions 320 x 270 x 80 mm

Mounting base M4 threaded mounting grid, 45 mm pitch, aluminum mount kit included

Accessory bag internal dimensions 220 x 160 x 70 mm 

Case features Rugged plastic case, side handles, carry handle, wheels, pressure purge valve, 

shoulder strap (optional)

Computer mounting type Docking

Electrical Specifications

DC input 10 – 32 VDC

Over-voltage protection, reverse polarity protection 

Battery type Lithium Ion

Battery Capacity 108 Wh

Battery Operation time 2 hours (typical)

Connections (all routed to Panasonic CF-31) 2 serial (RS-232), 5 USB, 2 Ethernet, 1 Composite Video in (IMPERX video 

device needed), 1 Microphone in, 1 Audio out, PCMCIA slot, HDMI

Connections to 17” display Composite Video (Optional), external VGA input ( Optional)

DC power output 1 12V 5A fused, 50 W

DC power output 2 12V 5A fused, 50 W

Antenna pass-through Two 50 Ohm antenna pass-through to upper lid

SMA-RP termination, RG 142

Computer Specifications (not included with GCS)

Model Panasonic Toughbook CF-31 ( all specifications as per manufacturer 

datasheets)

Durability MIL-STD-810G & IP65 certified (6' drop)

Display Type 13.1" XGA touch screen LED 1024x768

Brightness 1100 nits

17” Display Specifications 

Display Type 17 " TFT 1280 x 1024 (SXGA)

Optional touch screen

Optional AR glass

Brightness 1400 nits

Touchscreen type ( optional) Resistive 
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3 System Description

3.1 Power distribution system

Portable Ground Control Station has an integrated power system which has three independent power sources - one

external power input and two Lithium battery cartridges. Allthree power sources are interchangeable and GCS will 

switch automatically between availablesources, with preference given to the external power input.

The required external power input voltage is in the range of 10 to 32 Volts DC.In case both battery cartridges are 

discharged and external power voltage is below 10 Volts, the system shuts down automatically to prevent battery 

damage.

Figure 2 shows schematic drawing of the power distribution system in the GCS. External power and batteries are 

connected to the power source selector which provides power to the Laptop, LCD display and to two auxiliary power 

outputs located in MEC.Each power source and output is fused to protect the system from short circuit and overload;

fuses are marked with blocks numbered from F1 to F7. The external power input has additional overvoltage protection

and reverse polarity protection.

Figure 2 Power distribution diagramofModular Electronics Compartment

3.2 The modular electronics compartment

The modular electronics compartment (MEC), shown in Figure 3 allows installing the application-specific hardwareinside 

the GCS.Using theM4 mounting grid and included standard mounting kit, most hardware devices can be quickly installed

in MEC. Circuit boards can be installed directly on the base of the electronics compartment using standoffs. The MEC is 

protected by a removable lid, shown in Figure 4. Once the user-specific devices are installed in MEC, the lid is closed and 

remains closed, unless modification to the internal device configuration is required. The lid has an additional 

configurable connection panel as shown in Figure 4. This connection panel is used for routing additional connections or 

switches from equipment installed in the MEC. The GCS comes with three blank connection panels and with the 

additional label set described in Table 1. Connection panels can be further machined to accommodate additional 

connectors and switches.

External F7

Battery 1 F6

Battery 2 F5

Power Source Selector

F3

F2

F1

F4

LCD

DC OUT 1

DC OUT 2

Laptop
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Figure 3 Layout of the modular electronic compartment.

Figure 4 MEC protection lid with configurable connection panel.

Two SMA-RP terminated antenna pass-through cables (Figure 3) can be used to connect the SMA-RP antennas in the 

upper lid to the hardware devices located in the modular electronics compartment. Alternatively, antenna connectors 

can be located on the user-configurable connection panel as shown in Figure 4.

If Omni-directional antennas are used, it is convenient to use the integrated antenna pass-through. If antennas need to 

be routed outside the GCS, such as to an antenna mast or tracking antenna, it is more convenient to use the antenna 

connections located directly on the connection panel.

M4 Mounting Base

Removable lid

Dual antenna 

pass-through

Connection panel

User serviceable fuses
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Table 1 Label set description

Label Label Description

Antenna Connection

Antenna Connection

GPS connection

RC transmitter connection

DC OUT 1 

DC OUT 2 

USB 

Ethernet 

COM1 connection 

Composite video connection VIDEO IN

 |O|O| 1

DC 

DC 

RC

GPS

ANT 4

ANT 3
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3.3 Connections

Ground Control Station is designed to provide a complete set of connections for electronics located inside the MEC.

There are three groups of electrical connections in the GCS (Figure 5). Group 1 is intended for external device 

connectionand features one serial (RS-232) port, one microphone in, one Audio out and one USB. One VGA input for the 

17” display can be optionally installedin the GCS. This option allows users to switch between the VGA input and the 

Panasonic Toughbook. 

Group 2 is located inside the MEC and is used for connecting application specific hardware to the GCS. Group 2features 

one USB, one serial (RS-232), one Ethernet, one Composite Video (Video In 1) and two power outputs. Please note that 

for capturing composite video on the Panasonic CF-31, the IMPERX VCE-PRO capture device is needed. An optional 

Composite Video (Video In 2) can be factory installed to provide direct connection to the 17” display. The overview of 

Group 1 and Group 2 connectors is given in Figure 6.

Additional two USB ports and one Ethernet are accessible in Toughbookitself - these connections are marked as Group 3 

in Figure 5.

Figure 5 Communication diagram.

* IMPERX VCE-PRO capture device is needed.

** Video input connected directly to the 17” display (optional).

17” LCD

Docking station

USB 2

RS-232 (Com 2)

VGA IN (Optional)

USB 1

Ethernet 1

RS-232 (Com 1)

Video In 1*

Video In 2**

Group 2 (MEC)

Group 1 (EXTERNAL)

VGA switch 

(Optional)

Touchscreen

Toughbook

USB 3

Microphone in 

Audio Out

USB 4

USB 5

Ethernet 2

Group 3

VCE-PRO 

Capture
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Figure 6 Group 1 and Group 2 connectors overview.
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External power connector is the XLR type connector which is located in the top right corner of the MEC (Figure 6). The 

external connector pinout is given in Figure 7.

Modular electronics compartment provides two power outputs for application specific electronics, marked as ‘DC OUT 1’ 

and ‘DC OUT 2’, as shown in Figure 6. Each output provides up to 50 W of continuous power for internal electronics. 

Figure 8 shows power output socket polarity diagram.

Figure 7 External power socket pinout

Figure 8 Power output socket polarity diagram

GND + VCC

NC

+ Vs GND
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3.4 Switch description

The ground control station has five switches on the control panel as shown in Figure 9. Each switch is labeled and has 

two positions- “ON” and “OFF” respectively. Switch descriptions are given in Table 2. Additional switch is factory 

installed on the control panel if optional VGA input is integrated in the GCS.

Figure 9 Control panel

Table 2 Switch description

Switch name Description

MAIN Main power switch. Turns on the GCS.

LCD Turns on the 17”LCDdisplay.

DC OUT 1 Turns on power supply ‘DC output 1’ in MEC

DC OUT 2 Turns on power supply ‘DC output 2’ in MEC

PC When switch is “ON”,theToughbook is powered from 

the GCS’s power supply. When switch is 

“OFF”,theToughbookispoweredfrom its internal 

battery.

VGA (Optional) VGA source selection for the 17” display. When “PC” 

is selected, the display is connected directly to 

Toughbook’s VGA and acts as ‘extended display’. 

When “EXT” is selected, the display is connected to 

the external VGA source.
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4 GCSsetup

4.1 Electronics installation in MEC

The MEC lid can be opened by removingfour screws as shown in Figure 1. Application specific electronicscan be installed 

into the modular electronics compartment using M4 mounting grid and included standard mounting kit. Mounting kit 

includes 6 mounting brackets, 1 meter of 20mm Nylon webbing and 12 plastic slides.Place electronics in the MEC and 

attach it with the Nylon webbing to the mounting brackets. Use supplied M4 screws to attach mounting brackets to the 

MEC mounting grid. MEC has a suite of connections dedicated for application-specific electronics (please refer to section

3.4).

The example of application specific electronics installation is shown in Figure 10 and Figure 11. Figure 10 shows Procerus 

Technologies Kestrel autopilot (2) communication module installation. The module is connected to the DC OUT 1 power 

output which provides 12 V supply. The autopilot communication module uses ANT 1 pass-through connection for 

antenna and COM 1 for serial connection to Toughbook.

Figure 11 shows typical Kestrel autopilot communication module installation with Rotoconcept’s digital video receiver 

(3). In this configuration, video receiver uses ANT 1 and ANT 2 pass-through coaxial cables, DC OUT 2 power source and 

Ethernet connection for communication with Toughbook. The Procerus autopilot module is powered from DC OUT 1, 

and connected to COM1 serial. Antenna connectorislocated on the configurable panel on the top of the MEC protection 

lid.

Figure 10 Example of hardware mounting inside MEC using adjustable aluminum mounts
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Figure 11 Example of hardware installation in MEC for an unmanned aircraft vehicle

4.2 Battery installation

Ground control station uses two COTS Lithium-Ion MAKITA BL1830 batteries (Figure 12). Use only original 18V BL1830 

MAKITA batteries (4). To remove the battery push the release button as shown in Figure 12 and pull the battery 

cartridge away from the mount.

Thebatterycartridgesand external power supply can beremoved or connected any time during normal operation-the 

power system automatically controls power source selection. The external power is a priority source. 

Figure 12 Battery installation
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4.3 Battery charger

GCS comes with the standard MAKITA charger (Figure 13) for the BL1830 batteries. Charging time for one battery is 

approximately 30 minutes. Both 240 VAC and 110 VACcharger versions are available. The 12V DC charger version can be 

purchased separately.

Figure 13 MAKITA battery charge

4.4 External power connection

GCS comes with the AC/DC adapter (Figure 14) which is used as external power source from 110 – 240 VAC mains 

supply. When external power is connected, the LED which is located near the connector should light green.

Figure 14 AC/DC power adapter
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4.5 Toughbook installation

The GCS has an integrated CF-31 Toughbook docking station.The docking station is also compatible with the CF-30 

Toughbook.

Before installing the Toughbook, insure that protection lid on the back side is opened (Figure 15). Install the Toughbook 

into the docking station as shown in Figure 16.Once the Toughbook is located in the docking station, the docking handle 

needs to be engaged as shown in Figure 16. To remove the Toughbook from the GCS, first disengage the docking handle

and then remove the Toughbook.

Figure 15 Protection lid is opened

Figure 16 Toughbook docking
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4.6 Foldable stand

The optional foldable stand is availablefor the GCS. Place the GCS on the top of the stand as shown in Figure 17 and 

attach it to the stand using two clamps from both sides.

Figure 17 Foldable stand attachment
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5 Operation

To turn on the Ground Control Station turn on the “MAIN” switch on the control panel (see Figure 9 for details).All GCS 

power parameters are displayed on a dedicated display located in the upper part of the GCS (Figure 1).

5.1 Power Status Display

The power status display shows the GCS power status as shown in Figure 18.The following parameters are displayed on 

the power status display: the total system power, internal temperature, external power voltage and battery voltage.If

system is running on batteries, the display shows “arrow” above the appropriate battery symbol as shown in Figure 

18.Power status symbol description is given in Table 3.

Figure 18 Power status display

Table 3 Power status symbol description

Label Description

Ps System total power in Watts.

Ts Internal board temperature in Celsius.

DC External power voltage. Displays “LOW” 

when voltage is below 10 Volts.

BAT1 Battery 1 status. Upper value shows battery 

voltage. Lower value shows remaining 

battery capacity 

BAT2 Battery 2 status. Upper value shows battery 

voltage. Lower value shows remaining

battery capacity 

Ps 19W

Ts 21°C

DC LOW

BAT1 BAT2

19.7V

100%

17.2V

30%
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5.2 VGA setup

In order to configure the Toughbook connection to the 17” LCD, navigate to Screen Resolution window as shown in 

Figure 19 for Windows 7. Make sure that Toughbook is docked and 17” LCD is switched on as well as VGA switch 

(optional) is in “PC” position. Set 1280 x 1024 resolution for second display and select “Extend these displays” in the 

multiple display bar. Click “Ok” to save changes. 

Figure 19 Second display setup screen
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5.3 17” LCD display setup

Oncethe Ground Control Station is turned on, the 17” LCD display can be powered on to extend the Toughbook display. 

Alternatively, the 17” display can show the information from optional composite video input or optional VGA input. To 

turn on the LCD display, usethe“LCD” switch (please refer to section 3.4 for details). The LCD display brightness, contrast

and signal source can be configuredusingtheintegrated LCD control panel (Figure 20). The control panel has an additional 

LCD power switch which can be used to turn off the LCD.

Figure 20 LCD display control panel

To adjust brightness and contrast of the LCD press “OSD Menu” (On Screen Display) button on the LCD control panel.

Figure 21 shows the brightness sub page in the OSD menu. Press “OSD Menu” once more and select brightness or 

contrast using navigation buttons. Press “OSD menu” button and adjust brightness or contrast from 0 to 100 using 

navigation buttons. To save adjustment press “OSD menu” and navigate to for exit.

Figure 21 Brightness sub page

To select the signal source press “OSD menu” and navigate to the signal source sub page (Figure 22). Press “OSD menu” 

once more to enter into the sub page and select the necessary signal source by navigation buttons. In case of using 

Navigation

OSD Menu

LCD Power

Power indicator
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Toughbook VGA output or external VGA (optional) select VGA source. In case of using composite video source (Video 

input 2) select AV source. Press “OSD menu” to save changes and exit from the sub page.

Figure 22 Signal source sub page

The color adjustment should be done when Toughtbook is connected for the first time to the LCD. Press “OSD menu” 

and navigate to the color settings as shown in Figure 23. Select the automatic color adjustment and press “OSD 

menu” button. Make sure that Toughbook is connected to the LCD and PC switch is “on” before using the color auto 

adjust. This function will improve image quality but some minor flickering can be still observed on the 17” display while 

Toughbook is charging the internal battery. This is common issue for the external display connection through the 

docking station via the VGA. High charging current goes through the same docking connector as VGA signal.

Figure 23 Color settings sub page
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6 Troubleshooting

Problem Possible reason Solution

GCS is connected to external power

supply, but doesn’t work.

Not enough voltage Connect batteries or appropriate power 

supplyinthe 10 – 32 VDC range.

External power fuse is blown Check fuse F1. Replace if necessary.

Batteries are connected, but GCS 

doesn’t work

Both batteries are empty Replace batteries

Battery fuses are blown Check fuses F2 and F3. Replace if 

necessary.

17” display doesn’t work LCD display fuse is blown Check fuse F7. Replace if necessary.

LCD was switched off on the 

control panel

Turn on LCD using power button on the 

LCD control panel

17” display shows “No signal” Dock handle is not engaged Check that Toughbook is docked.

Wrong VGA configuration Refer to section 0.

VGA switch position is wrong Check VGA switch position

Wrong signal source Refer to section 0.

No power at DC OUT 1. DC OUT 1 fuse is blown Check fuse F5. Replace if necessary.

No power at DC OUT 2. DC OUT 2 fuse is blown Check fuse F6. Replace if necessary.

No power output to the Toughbook 

when switch “PC” is on.

Fuse is blown Check fuse F4. Replace if necessary.
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7 Contacts

Please use the following information to contact UAV Factory:

UAVFACTORY LTD.

24A-52 Ganibu Dambis

Riga, Latvia, LV1105

Tel: +371 29119398

Email: info@uavfactory.com

8 User manual version history

Version Comments, Updates Date Author

1.0 First manual version for Portable Control 

Station

03.06.2012 AG

1.1 Added note regarding the 17” display and 

VGAsetup

07.23.2012 AG

9 References

1. Panasonic. [Online] http://www.panasonic.com/business/toughbook/fully-rugged-laptop-toughbook-31.asp.

2. Procerus Technologies. [Online] http://www.procerus.com/index.php.

3. Rotoconcept Robotics. [Online] http://www.rotoconcept.com/.

4. Makita BL1830. [Online] http://www.makita.com.au/products/lxt/lithium-ion/item/lithium-ion/bl1830-18v-li-ionbattery?Prodid=.