Mcmurdo C1 S-VDR Service Manual (1)

C1 S-VDR Service Manual

Commercial in confidence

36-261

Table of Contents 1.

Introduction ..........................................................................................................1 1.1 Scope..............................................................................................................1 1.2 Applicability .....................................................................................................1 1.3 Servicing equipment .......................................................................................3 1.4 Safety notices .................................................................................................4 1.5 False alarms ...................................................................................................6 1.6 Deactivating the EPIRB ..................................................................................6 2. Assessment ..........................................................................................................7 2.1 Maintenance tasks..........................................................................................7 2.2 Routine testing ................................................................................................7 2.3 Assessment ....................................................................................................8 3. Maintenance Procedures ..................................................................................11 3.1 Inspection......................................................................................................11 3.2 Functional tests.............................................................................................12 3.3 Message read ...............................................................................................13 3.4 Internal inspection.........................................................................................14 3.5 Disassembly..................................................................................................15 3.6 Reassembly ..................................................................................................20 3.7 Leak testing...................................................................................................28 3.8 Battery replacement......................................................................................29 3.9 Disposal of batteries .....................................................................................29 3.10 HRU Replacement Kit...................................................................................30 3.11 Programming ................................................................................................34 3.12 Data Recovery ..............................................................................................34 4. Fault finding........................................................................................................36 4.1 Confirming PCB faults ..................................................................................36 5. Repair procedures .............................................................................................37 6. Spares .................................................................................................................38 7. Appendix 1: Specification .................................................................................40 DRU section.............................................................................................................40 EPIRB section..........................................................................................................40 Appendix 2 : IMO recommendations.......................................................................41

This document is McMurdo Limited copyright (©) and contains proprietary owned intellectual property rights and confidential data. All rights are strictly reserved. The information must not be used except for the agreed purpose. Unauthorised use, reproduction or issue to any third party is not permitted without the prior written authority of McMurdo Limited. This document is to be returned to McMurdo Limited when the agreed purpose is fulfilled. C1 S-VDR service manual

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1. INTRODUCTION The Simplified Voyage Data Recorder (S-VDR) Float Free Capsule (FFC) provides two essential safety features: a rescue beacon and a store of vessel data. The Capsule provides the functions of an Emergency Position Indicating Radio Beacon (EPIRB), which uses the COSPAS-SARSAT satellite network to pass distress alerts to the rescue authorities. Under normal conditions position information is derived from a GPS module; this greatly enhances the accuracy of the position transmitted to the rescue services. The S-VDR FFC maintains a store of information concerning the position, movement, physical status, command and control of a vessel over a 12-hour rolling period. Should any incident occur which requires investigation, the information contained in the Capsule can be made available to both the Administration and the ship-owner. This information may assist during any subsequent investigation to identify the cause(s) of the incident. The final recording medium is an ATA FLASH drive system installed in the Capsule. The Capsule is designed to float free automatically if the ship sinks, and to transmit its current location information through the COSPAS-SARSAT satellite network. The Capsule complies with the requirements of IEC 61996-2. The Capsule is capable of being accessed following an incident but is secure against tampering. The Capsule encloses the Data Recording Unit (DRU) containing the recording medium. The final recording medium is not accessible by standard operating procedures during normal ship operations. Stored information can be retrieved to an external device via the Data Collection Unit (DCU) without opening the protective Capsule. There are 2 variants of the DRU: An Ethernet 10/100baseT interface which requires 24 V DC (nominal) external power. This is available as 2GB or 6GB. A Firewire DRU which interfaces through CAT5 cable and operates on 27V. This is available as 6GB or 9GB.

1.1 Scope This manual provides the complete instructions issued to shore-based maintenance (SBM) providers to enable routine and emergency servicing of the S-VDR equipment listed below. This manual represents the original equipment manufacturer’s (OEM) service documentation applicable to these products.

1.2 Applicability This information applies to the following S-VDR equipments: • • • • •

36-001-001A Firewire 6GB 36-001-002A Ethernet 2GB 36-001-003A Ethernet 6GB 36-001-004A Firewire 9GB 36-001-005A Ethernet 2GB

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S-VDR EPIRB in mount

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1.3 Servicing equipment All agents are obliged to possess specialised equipment to ensure that S-VDRs are serviced correctly. A message reader (ARG5410 or equivalent) is mandatory; service agents in countries where RF power measurement is required must also have a suitable RF power meter and attenuators. Equipment: Message reader (eg Sartech 5410) Programming Kit PC computer and printer Static safe work area with operator wrist strap Magnet Conductive metal plate or shorting link Screened enclosure Test Fixture Handtools: Calibrated torque driver (60-85cNm) with attachments: 7mm A/F (M4) socket Small cross-headed screwdriver Medium Cross-headed screwdriver 11mm A/F box spanner or socket 10mm A/F spanner 19mm A/F spanner

Antistatic precautions The electronics sections of the S-VFR are sensitive to electrostatic discharge (ESD) which can cause immediate or hidden long term damage. It is important that the PCBs are only handled under suitable antistatic conditions. Ideally, a fully grounded workstation, which has conductive surfaces to avoid the build up of static charge, should be used. As a minimum, the operator must be connected to a good earth point through a resistance of 1Mohm. This is usually achieved by wearing a suitable wrist strap.

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1.4 Safety notices Please read the following for your safety: This product has been assessed as presenting negligible hazard in a sealed serviceable state.

Safety analysis The following table summarises the nature of the hazard which may be present when the unit is opened or serviced; each hazard is discussed at greater length in the detailed sections. Hazard cause Lithium battery Strobe Radio frequency radiation

Hazard identification Explosive risk, corrosive fumes, fire, biological hazard Bright light Physiological hazard

Precautions Handle appropriately, avoid contact Avoid staring at light Avoid close or prolonged exposure

Lithium batteries

Hazardous chemicals

Wear gloves

The batteries used in these products contain Lithium (Li). Lithium is inflammable, reacts violently with water and constitutes a biological hazard. These batteries are HAZARDOUS if short-circuited, punctured, incinerated or deformed. Lithium batteries must not be short circuited. Lithium batteries must be handled, transported and disposed of using appropriate safety precautions. The use of rubber gloves as a routine precaution is recommended. The Lithium batteries contain 21 g of Lithium; local and international shipping regulations may require certain packaging standards and labelling. Batteries have special disposal requirements. In the event of leakage of the battery electrolyte (which can be recognised by a pungent odour), take care to avoid contact, particularly with open wounds; do not ingest the material. Do not attempt to discharge a leaking battery – remove it using appropriate handling materials and seal in a plastic bag, then dispose of it through an approved environmental disposal agent, or in accordance with local regulations.

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Strobe radiation The LED strobe light fitted to the EPIRB section produces intense flashes of light. No damage is likely to be caused by intermittent exposure, but prolonged exposure should be avoided.

Radio frequency radiation

Radio frequency radiation

The EPIRB section produces radio frequency radiation when it is activated. The radiated level is below 13W with a duty cycle of 1%. Due to the low duty cycle this is not considered to be a hazard

General precautions for chemical agents (adhesives, greases, IPA) Observe all safety precautions relevant to the country of operation. As a general rule, protective overalls, gloves and goggles should be worn when handling these chemical agents, but different countries may have additional requirements which must be observed. Ensure that all chemical agents are handled in accordance with the manufacturer's instructions, and that suitable protective clothing is worn. Make sure that the working area is well ventilated, and that chemical substances are not left exposed. Observe good hygiene practices; do not eat, drink or smoke when handling chemicals. Cyanoacrylate adhesives bond instantly on contact. If skin is bonded, it can usually be released by a gentle peeling action; above all, do not panic and avoid direct pulling on bonded skin. Read the manufacturer's instructions before using any chemical agent.

Wear goggles

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Wear overalls

Wash hands

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Wear gloves

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1.5 False alarms Every care must be taken to avoid the generation of false alarms. The S-VDR has a sea switch; it is not uncommon for these to activate in rough seas or heavy rain because the S-VDR is badly fitted in its mounting bracket. The mounting bracket incorporates a magnet to disable the S-VDR. If the S-VDR is wrongly fitted the cutout is not actuated by the magnet, so heavy weather may activate the sea switch. To prevent this, ensure that the S-VDR is correctly fitted. If for any reason the S-VDR is activated outside a screened enclosure (other than as a self test and for more than 120 seconds), it must be assumed that a false alarm has been generated. It is not sufficient to just de-activate the S-VDR immediately – the rescue services must be informed that there has been a false alarm. Use any means available to contact the coastguard or the nearest Maritime Rescue Coordination Centre (MRCC); state that there has probably been a false alarm, identify the location of the S-VDR and if possible give the unique ID.

1.6 Deactivating the EPIRB Remove the S-VDR from any water and dry the sea switch contacts at the bottom of the unit. Wait for a few seconds for the unit to de-activate automatically. If it fails to deactivate, press the OFF switch. The FFC should stop flashing within one minute. If the FFC continues to transmit, it may have a fault. The next stage is to attempt to deactivate the unit by a magnet. For this purpose the FFC may be fitted to its mount, or a suitable magnet may be placed against the case alongside the reed switch. See page XX. If this does not stop the FFC, there is definitely a fault. To prevent further nuisance, it is recommended that the unit is allowed to exhaust its battery whilst the alarm signals are suppressed. The recommended procedure is: Make another attempt to deactivate the EPIRB, as described above. Place in a metal enclosure, or wrap in metal foil. Leave for three days until the battery is exhausted. It is also possible to open the case of the FFC and disconnect the battery. However, this should be regarded as a last resort as 10 screws have to be removed and further internal damage may occur. If this has to be done, once the FFC is open then disconnecting the battery lead stops all activity. See section 3.5. .

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2. ASSESSMENT 2.1 Maintenance tasks Servicing agents (Shore Based Maintenance (SBM) providers) are reminded that it is their responsibility to ensure that the procedures herein are followed, that only OEM approved parts are fitted, and that good common practice is observed. False alarms caused by inadvertent activation must be avoided The functions which can be performed by SBM providers are: • • • • • • • • •

Routine testing Reprogramming Message reading and verification Power measurement Battery replacement Leak testing HRU replacement Data recovery Fault diagnosis and repair

2.2 Routine testing An EPIRB should be tested monthly by its owner to ensure functionality. Wherever possible the EPIRB should also be inspected for mechanical damage. In accordance with IMO guidelines (Circ 1040) an EPIRB fitted to a GMDSS compliant vessel is recommended to undergo a yearly on board inspection. In accordance with IMO guidelines (Circ 1039) an EPIRB fitted to a GMDSS compliant vessel is recommended to undergo a five yearly SBM inspection. Whatever the reason for the return of an EPIRB to a shore-based maintenance agent, the EPIRB must be subjected to a full assessment before any other action is taken. The agent has a responsibility to ensure the EPIRB is completely serviceable and is fit for its purpose.

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2.3 Assessment Every S-VDR returned for servicing, of whatever nature, must be fully assessed to determine its operational status. The diagram shows the tasks which must be carried out for each servicing situation.

RECEIPT

HRU change

Fit HRU Mark dates

Assessment Inspect Functional test Message read

Reprogram

Fault found

Battery change

Disassemble

Disassemble

Program Print forms Complete labels

Internal inspection

Internal inspection

Fault find

Fit battery Mark dates

Repair Reassemble Leak test

Functional test Message read

RETURN If the FFC is opened for any reason, it must be fitted with a new sealing kit (the gasket is not re-usable). It must then be subjected to a leak test.

Assessment form The assessment form, shown on the next page, is an essential tool in performing diagnosis. It may be used to support customer billing, and must accompany any warranty return to the manufacturer. The first section of the form records the customer, the S-VDR and the reason for return (as 'Customer comments'). It is essential to record the identity details from the EPIRB top cone, as these will be necessary for comparison with the transmitted data. The expiry date must be noted; if less than 6 months life remains, a battery change should be recommended to the customer. Opening the FFC for internal inspection is only required if a problem is found.

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S-VDR ASSESSMENT

Ref No

Date

Customer

Vessel

Type

Man. Serial No

Battery expiry date

Country

Call sign/MMSI

MMSI Call sign

UIN

Category

Auto/Manual

Serial






Customer comments

Warranty claim

INSPECTION

YES/NO

Auto bracket








Magnet present Strap/buckle intact

HRU date

Plastic condition Cables OK BIM

FFC







Integrity seal intact Plastic OK Antenna OK Lanyard OK

Comments

FUNCTIONAL TEST Live mode

Sea Switch

Self test


Deactivates
Does not activate with magnet


Red LED on

Activates

3 strobe flashes LED



Green

Strobe activates within 8 s







Comments

MESSAGE READ 121 sweep heard 406 frequency OK





ID

MMSI/Call sign/Serial no

Country Man Serial No

EPIRB No

Auto/Man

Comments

INTERNAL INSPECTION Water ingress Plastic damage





PCB corrosion Switch fault

Required






PCB fault


Battery voltage volts

Comments

New Parts HRU kit Battery kit Top cone kit EPIRB PCB Lanyard Sealing Kit DSM Other:

Conclusions








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Assessed by

Signed

Date

FINAL LEAK TEST

Pass/Fail

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3. MAINTENANCE PROCEDURES 3.1 Inspection Release mount inspection 1. Check the strap for correct tension. Hold the FFC in its mount, locate the HRU in its holding lugs and clip the strap around the FFC. Slowly operate the strap latch and assess how much force is needed to close the latch. It should take a reasonable amount of force to close the latch. If the latch closes too easily then the strap is too loose; there is a danger that the FCC could be fixed with the locating lug not engaged. Add detail. 2. Remove the FCC from its mount, unhook the strap from the mount and remove the strap with the HRU attached. Read the expiry date marked on the HRU. If there is less than 3 months to run before expiry then advise that the HRU is replaced. 3. Check that the release mount is not fractured or deformed. 4. If the mount needs cleaning, use isopropyl alcohol (IPA). 5. Inspect the mount for serviceability. The strap, the latch and its safety pin must all be fully operational. The presence of small (pin-head) spots of rust on the metal parts is acceptable. 6. Check the labels fitted to the release mount for damage, readability and adhesion. 7. Remove the screw retaining the mount bracket and inspect the BIM.

BIM Inspection The BIM outer case should be in good condition – there should be no visible damage or rusting. Remove the top cover and inspect the glands – these should be tight. Tighten to 300cNm+/-25cNm using a 19mm torque driver if required.

FFC inspection 1. Examine both cones for signs of cracking or fracture that might lead to water ingress. Look in particular around the switches and the 10 bolt mounting holes as these are under the most stress. Also look for splatters of paint on the cones as the solvent within the paint might have weakened the plastic. If any cracks or fractures are present, the cone(s) must be replaced. 2. Check for any evidence of attempts at unauthorized disassembly. 3. Slowly turn the FFC upside down. If any water collects in the top of the antenna housing, then the FFC has leaked and must be serviced. Also inspect the top of the circuit board through the clear top cone for traces of white powdery corrosion. If any corrosion is present then it is very likely that the FFC has leaked and so must be serviced. 4. Check the battery expiry date marked on the FFC bottom cone has at least 6 months left to run. 5. Check TEST and ON switch boots for damage. 6. Check the labels fitted to the FFC for readability and adhesion. 7. Ensure the integrity seal is intact. This is essential to guarantee that the battery has not been discharged. 8. Examine the sea switch contacts on the bottom cone. If there are signs of rust, white powdery corrosion or salt deposits then the contacts must be cleaned. C1 S-VDR service manual

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3.2 Functional tests The tests detailed in this section confirm that the FFC is fully functional. Equipment Required Special screened/anechoic chamber Message Reader Magnet Conductive plate/shorting link

As required Sartech 5410 or equivalent 82-209 or similar Any suitable

Sea switch Warning: This test must be performed quickly. The FFC must not be allowed to be active for more than 120 seconds, otherwise it will transmit an alarm. 1. Stand the FFC on the conductive metal plate or short the sea switch screws using a link wire. Within approx 8 seconds the FFC must activate (start to flash). 2. Immediately place the magnet in the position shown. Add picture The FFC must deactivate (stop flashing) immediately. Remove the magnet and the FFC should re-activate within approx 8 seconds. 3. Immediately lift the FFC off the metal plate. Within approx 8 seconds the EPIRB should deactivate.

Self test 1. 2. 3. 4.

Press and hold the TEST button. The red LED should immediately light indicating self test is running. On successful completion of the self test sequence the green LED will flash 3 times and the strobe will flash 3 times. Release the TEST button

CAUTION: Do not subject more than one FFC to self test at any time, as two units may interfere during self test.

ON test Warning: This test must be performed quickly. The FFC must not be allowed to be active for more than 120 seconds, otherwise it will transmit an alarm. If the test is to be prolonged, a screened enclosure must be used. The integrity seal will be broken during this test – ensure that a replacement is available. 1. Pull off the ON switch cover. 2. Press the ON switch. 3. Allow the strobe to flash three times 4. Press the Test button to switch the unit off. The unit should turn off within 2 seconds. Fit a new integrity seal.

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3.3 Message read Part of the IMO requirement is that the SBM provider verifies the message. This can be done with a "Message Reader". A typical instrument is the ARG5410. This model will be used to describe the process. Operation of the Reader is detailed in its handbook and will not be repeated here. The procedure is as follows: 1. 2. 3. 4.

On the Reader select RECV mode Position the Reader approx. 1m (3 feet) from the FFC Perform a self test on the FFC After about 12 seconds the 121.5MHz detector should emit three bursts of sound

5. 6. 7. 8.

The Reader should beep and report S’TEST OK The Reader will revert to its Menu. Select VIEW mode Use ← → keys to view the decoded 406MHz message content Confirm the frequency was within 406.020 – 406.030

This proves the 121.5MHz homer is radiating and modulating correctly.

This proves the 406MHz transmitter is radiating within the correct frequency band. If the ARG5410 Reader is not used, then another facility for measuring the 406MHz frequency must be provided (a spectrum analyser for example).

9. Confirm the 15 digit ID agrees with FFC identity label UIN This proves the 406MHz transmitter is modulating correctly and the EPIRB is programmed with the correct vessel identity. If the ARG5410 is not used then another facility for message decoding must be provided (other message readers).

10. Confirm the Flag state and the Serial No / MMSI / Callsign agrees Typical screen

Q 11:25 Mesg#11 S’TEST OK ID: 9D0D071D3B00013 406.0257 MHz PASS

Common problems Audio tone

If not heard then reduce range from 1m to 0.3m to help.

Frequency

If outside limits, repeat the self test two or three times in rapid succession to provide a warm up time. Repeat test.

Bad frame

This error message occurs if the Reader fails to synchronize. This occurs approx. 10% of the time. Repeat test multiple times. If EPIRB achieves