Mcmurdo E-5 Service Manual
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mcmurdo E5/G5 EPIRB Service Manual
Commercial in Confidence
82-992 Iss 1
Table of Contents 1.
Introduction ..........................................................................................................3 1.1. Scope..............................................................................................................3 1.2. Applicability .....................................................................................................3 1.3. Servicing equipment .......................................................................................4 1.4. Safety notices .................................................................................................5 1.5. False alarms ...................................................................................................7 2. Assessment ..........................................................................................................9 2.1. Maintenance tasks..........................................................................................9 2.2. Routine testing ................................................................................................9 2.3. Assessment ..................................................................................................10 3. Maintenance procedures...................................................................................13 3.1. Inspection......................................................................................................13 3.2. Functional test...............................................................................................15 3.3. Message read ...............................................................................................17 3.4. Internal inspection.........................................................................................18 3.5. Disassembly..................................................................................................19 3.6. Re-assembly .................................................................................................22 3.7. Leak testing...................................................................................................25 3.8. Battery change..............................................................................................26 3.9. Reset the Run Time counters on the PCB ...................................................28 3.10. HRU replacement......................................................................................29 3.11. Programming.............................................................................................30 4. Fault finding........................................................................................................32 5. Repair procedures .............................................................................................35 6. Spares .................................................................................................................36 Appendix 1 : Specification .......................................................................................37 Appendix 2 : IMO recommendations.......................................................................38
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. EPIRB service manual
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1. INTRODUCTION The Emergency Position Indicating Radio Beacon (EPIRB) is a device used to alert search and rescue services in the event of an emergency. It activates via a sea water switch whilst floating in the sea. The EPIRB contains the following three functions: 406MHz transmitter
A powerful 5 Watt transmission is encoded with either a unique serial number or the vessel’s call sign / MMSI. The signal is relayed via satellite to the rescue centre.
121.5MHz transmitter
A low power transmission is amplitude modulated with a swept audio tone and acts as a homing beacon. When the rescue services get close this allows them to direction find on the signal.
Flashing light (strobe)
A bright light flashes every 2.6 seconds as a visual aid during the last stage of rescue.
GPS receiver (optional)
The module receives and decodes the Global Positioning System signals from a satellite network and computes the position of the EPIRB.
The vessels flag state and the vessel identity or serial number is programmed into the EPIRB as part of the 406MHz transmission, thus making the EPIRB unique. Transferring an EPIRB to another vessel either involves re-programming, or reregistration.
1.1. Scope This manual provides the instructions to enable routine and emergency servicing of the EPIRB equipment listed below. This manual represents the original equipment manufacturer’s (OEM) service documentation applicable to these products.
1.2. Applicability This manual applies to the following 406MHz EPIRB equipment: • • • • • •
McMurdo G5 McMurdo E5 Sailor SGE406-II Sailor SE406-II Simrad EG50 Simrad EP50
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1.3. Servicing equipment The following tools and equipment is required to carry out the servicing detailed in this procedure. Equipment: Message reader Leak testing equipment Static-safe work area with operator wrist strap Multimeter with voltage and resistance scales Programming kit : 82-950A Light pen 82-951A EPROG5 (McMurdo variant) Bar magnet or manual bracket with incorporated magnet Shorting link for sea switches Battery discharge load (made on-site as required) Handtools: Calibrated torque driver (0.1 – 1Nm) with attachments: 7mm A/F socket (M4) Small cross-headed screwdriver Large cross-headed screwdriver
Antistatic precautions The electronics section of the EPIRB is sensitive to electrostatic discharge (ESD) which can cause immediate or hidden long term damage. It is important that the PCB is 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 information 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
IPA
Hazard identification Explosive risk, corrosive fumes, fire, biological hazard Bright light Physiological hazard
Irritation, highly flammable
Precautions Handle appropriately, avoid contact Avoid staring at light Avoid close or prolonged exposure. Do not touch the antenna during 406MHz transmissions Avoid contact, ventilate well
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. 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 strobe lights fitted to EPIRBs produce intense flashes of light. No damage is likely to be caused by intermittent exposure, but prolonged exposure should be avoided.
Radio frequency radiation An EPIRB 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; however, it is advisable to avoid touching the antenna of a transmitting EPIRB.
Radio frequency radiation
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.
Read the manufacturer's instructions before using any chemical agent.
Wear goggles
EPIRB service manual
Wear overalls
Wash hands
Wear gloves
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1.5. False alarms Every care must be taken to avoid the generation of false alarms. Modern EPIRBs are activated by sea switches. It is not uncommon for these to activate in rough seas or heavy rain because the EPIRB is not fitted or badly fitted in its mounting bracket. The mounting bracket incorporates a magnet to disable the sea switch. However, if the EPIRB is wrongly fitted the magnet fails to disable the sea switch, so heavy weather may activate the EPIRB. To prevent this, simply ensure that the EPIRB is correctly fitted. For test purposes the EPIRB may be operated in the following ways without generating a false alarm: 1. Self test mode (but avoid repetitive self tests) 2. Live mode for less than 50 seconds (after 50s a live transmission is made) 3. Live mode in a screened enclosure If for any reason the EPIRB is activated outside a screened enclosure (other than as a self test) for more than 50 seconds, it must be assumed that a false alarm has been generated. If this occurs: 1. Deactivate the EPIRB (see below). 2. 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 EPIRB and if possible give the EPIRB ID.
De-activating a live EPIRB Remove the EPIRB from any water and dry the outside. Wait about 8 seconds for the unit to de-activate automatically. If it fails to deactivate ensure that the activation switch is fully off (slide to right). If the EPIRB continues to transmit, it may have 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: 1. Cut off the antenna. 2. Place EPIRB in a metal enclosure, or wrap in metal foil. 3. Leave for three days until the battery is exhausted. If it is absolutely necessary to fully disable the EPIRB (by unplugging the battery) then please see the relevant section of this manual.
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2. ASSESSMENT 2.1. Maintenance tasks Service providers are reminded that it is their responsibility to ensure that the procedures herein are followed, that only McMurdo approved parts are fitted, and that good common practice is observed. False alarms caused by inadvertent activation must be avoided. We recommend that EPIRB testing is only done in self-test mode, where possible, to avoid false alarms. The functions which can be performed by service providers are: • • • • • • • • •
Routine testing Reprogramming Message reading and verification Power measurement Battery replacement Battery life/GPS test reset Leak testing HRU replacement 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. An EPIRB fitted to a GMDSS compliant vessel is recommended to undergo an inspection at yearly intervals and shore based maintenance every 5 years (maximum). To carry out shore based maintenance requires a certification by the manufacturer of the EPIRB. Whatever the reason for the return 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. Included in the user handbook are full details on: Installation Emergency procedure GPS operation test LED operation Therefore these items are not repeated in this manual.
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2.3. Assessment Every EPIRB 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
Fault found
Battery change
Disassemble
Reprogram
Disassemble
Program Print forms & labels Mark HRU date
Internal inspection
Internal inspection
Fault find
Fit battery Mark Dates
Repair
Reassemble
Reassemble
Reset EPIRB
Leak test
Functional test Message read
RETURN
If the EPIRB is opened for any reason, it must be fitted with a new sealing kit.
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 EPIRB and the reason for return (as 'Customer comments'). It is essential to record the identity details from the EPIRB rear label, 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. Procedures for the rest of the form are detailed in section 3. Opening the EPIRB for internal inspection is only required if a problem is found.
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EPIRB ASSESSMENT
Ref No
Customer
Vessel
Type
Man. Serial No
Flag
Call sign/MMSI
ID
Category
Date
Battery expiry date
-
MMSI Call sign
Auto/Manual
Serial
Customer comments
Warranty claim
YES/NO
INSPECTION Manual bracket Magnet present Clip functional
Auto bracket
EPIRB
Cover intact Lever arm operates Magnet present
Tamper intact Plastic acceptable Antenna acceptable Lanyard OK
HRU date
Comments
FUNCTIONAL TEST Sea Switch
Self test
OFF with magnet in 8s Does not activate with magnet
LED on
ON within 3 seconds
Live mode
Buzzer Strobe 3 flashes
LEDs/buzzer on Strobe consistent Switches off
GPS Test
Pass
Comments
MESSAGE READ ID OK 406 frequency OK
MMSI/Call sign/Serial no
Country Man Serial No
EPIRB No
Auto/Man
Comments Required
INTERNAL INSPECTION
Water ingress
Battery OK
PCB corrosion Switch fault
PCB fault Plastic damage
Battery voltage
(optional)
________________V
Comments
New Parts Battery kit Sealing kit Antenna Lens dome Body PCB Assy Label kit F/F label kit
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Conclusions
Assessed by
Signed
Date
FINAL LEAK TEST
Pass/Fail
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3. MAINTENANCE PROCEDURES 3.1. Inspection Manual bracket If this has been returned, it should be checked as follows: Magnet
Confirm magnet is still potted into bracket and is not rusting
Release clip
Check for correct and smooth operation. R-clip should engage.
Carry safe
carry safe section should disengage from main bracket.
Automatic bracket (enclosure) If this has been returned, check it as follows: Cover intact
Ensure offset weight is secure. Check cover retaining pin is present and attached to cover. Confirm identity label on side agrees with rear of EPIRB.
Lever arm
Check magnet present. Release HRU (press down and slide upward) Confirm lever arm moves freely and is secure.
HRU expiry date
Side of HRU should be marked with expiry date. Confirm date is acceptable. If less than 3 months left, recommend a new HRU to customer Confirm HRU expiry date is marked on cover side label.
Press lever arm down and refit the HRU. Ensure washer engages (section 3.10).
EPIRB inspection Note that the EPIRB is designed to allow water to circulate around the outer edge of the dome (inside the outer clear plastic edge but outside the waterproof seal), consequently a volume of water in this area is of no consequence. Tamper seal
Check tamper cover/frangible tab is intact and holding switch to right. If tab is damaged or is non-standard in any respect, battery state must be considered suspect. Contact customer to confirm any history of EPIRB activation.
Battery expiry
If there is less than 6 months left to run, contact customer and recommend battery replacement.
Lanyard
Lanyard should be neatly wound onto bobbin. Rewind if required. End of lanyard shall be firmly attached to hole in rear of EPIRB. Bobbin should clip into rear of EPIRB and remain in place.
Sea Switch
Check that the sea contacts are clean and free from paint or grease.
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Plastic damage
Check plastic body for signs of cracking or wear. Check clear lens dome for cracking, especially around screws.
Water ingress
Check if water is visible inside the lens dome or on the PCB.
Antenna damage
If covering is worn to expose steel inside, replace antenna. Antenna should not show signs of being creased at any time.
Identity
Ensure that the Identity information is clear – replace (using programming facility) if necessary.
If the EPIRB or its mounting needs cleaning then this should be done using warm soapy water and a damp (not wet) cloth. Do not use strong detergents or solvents.
Do not paint the EPIRB or its mounting Do not clean with detergents or solvents During vessel cleansing or painting remove the EPIRB and its mounting.
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3.2. Functional test Self test 1. 2.
3. 4.
Press the TEST button until the red LED lights indicating that the self test is running, then release the button. The EPIRB will test its internal components and then make test transmissions at 121.5 and 406 MHz whilst monitoring the transmitter output. If all tests are successful, the buzzer will sound and the red LED and white strobe LED will flash together a number of times. If any test is unsuccessful, nothing will flash and the red LED will go out.
Operation of this test for the Smartfind Plus is identical, except that the green LED will also flash. The number of times the LEDs flash is an indication of the accumulated time the battery has been in use – as long as the strobe flashes at least once then the unit has passed self test. Accumulated Battery Use (hours) 0 to 4 5 to 6 More than 6
Number of flashes/beeps 3 2 1
However as expected battery use per year is only 32 minutes (12 Self tests and 2 off GPS tests) – it is recommended that any unit which has a reduced number of LED flashes should have the battery replaced in order to ensure that the unit will operate for 48 hours in an emergency. Note: The 121.5MHz transmission made during self test is unmodulated. Therefore it will not be picked up by the ARG5410 message readers or by a air band radio receiver. The self test inherently checks the 121.5 and 406 power as part of the test. However if the 121.5MHz must be checked then a Spectrum Analyser or the BT100A EPIRB tester will be required to record the transmission.
Sea switch 1. 2. 3. 4. 5. 6. 7.
Short-circuit the sea switch contacts The red LED should light within 3 seconds and the strobe flash Remove the short circuit The red LED should go out within 8 seconds Place unit into manual bracket or apply magnet to disable the sea switch. Short-circuit the sea switch contacts again The unit should not activate.
The unit must not be allowed to activate for more than 50 seconds to avoid a live transmission. If the red LED starts to flash, you have made a live transmission. EPIRB service manual
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Live test The live test detailed here is for use if a screened enclosure is not available. It is advised that all live testing should be carried out in a screened enclosure. 1.
Use a probe to push back the switch arm and then slide the switch to the ON position.
2. 3.
Ensure that the red LED comes on. Confirm the strobe flashes regularly every few seconds, the green (if fitted) and red LEDs lights and the buzzer sounds. Return the switch to the OFF position to switch the EPIRB off.
4.
This must be done within 50 seconds to avoid a live transmission. If the red LED starts to flash, you have made a live transmission.
GPS operation test The Smartfind Plus (G5) variant has a utility to allow the GPS to be tested. The procedure for testing is included in the user manual and so will not be repeated here. NOTE: The green LED (indicating successful test) only lights at the end of the test while the buzzer/strobe are flashing.
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3.3. Message read To comply with SBM and annual maintenance the service provider must verify the EPIRB 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 EPIRB On the EPIRB press the TEST button After about 4 seconds the Reader should then beep and report DECODING MESSAGE followed by S’TEST OK 5. The Reader will revert to its Menu. Select VIEW mode 6. Use ← → keys to view the decoded 406MHz message content 7. Confirm the frequency was within 406.020 – 406.030 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).
8. Confirm the 15 digit ID agrees with EPIRB rear identity label UIN This proves the 406MHz transmitter is modulating correctly and the EPIRB is programmed with the correct identity. If the ARG5410 is not used then another facility for message decoding must be provided (other message readers).
9. 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
Will not be heard with Smartfind product.
Frequency
If outside limits, repeat self test a number of times. (Provides 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. Move location of EPIRB/reader. Also note that an exhausted reader battery causes bad frames.
Normal mode It is possible to message read in live mode provided the EPIRB is in a screened enclosure. In this case the Reader reports NORMAL OK and the first 3 bytes of the full hex message are FF FE 2F… instead of the usual FF FE D0… for self test mode.
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3.4. Internal inspection Internal inspection is important both for diagnosing faults and for detecting possible faults early. Internal inspection is required under the following conditions: • • • • •
A fault has been observed and needs to be diagnosed If there is any indication of water inside the EPIRB Any salt deposit or corrosion is visible inside Signs of any cracking of the plastic parts Any time the EPIRB is opened for other reasons
Sections 3.5 and 3.6 detail how to disassemble the EPIRB and then re-assemble it. These sections should be followed, but using the notes below as guidance on what to look for during the disassembly process.
Prior to opening EPIRB • •
Inspect lens and body for signs of levering with screwdrivers Inspect antenna for sharp bends, which indicate the EPIRB has been dropped.
With dome removed •
If there is a pungent smell, then suspect that one of the Lithium battery packs have leaked. See section 1.4 for advice. Wear rubber gloves. Damaged lithium batteries may be unstable and pose a serious safety hazard. Leakage usually damages circuit boards, so it is often necessary to scrap the EPIRB without further investigation.
•
If the EPIRB has an electrical fault, make measurements on the battery.
•
Check Sea switch contacts internally.
•
Check circuit board for white salt deposits, dull grey corrosion or wetness. If any corrosion is evident the PCB should be replaced.
•
Check plastic parts, especially screw positions, for signs of cracking.
•
Check condition of EMC coating inside body. Green patches mean water ingress.
With battery removed •
Check condition of weight. Green deposits mean water was present
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3.5. Disassembly EPIRB disassembly should be done under static safe work condition (section 1.3.).
a) Dome moulding removal 1.
Invert unit and using large posi-driv screwdriver remove 3 off screws and washers.
2.
3.
Carefully pull the dome moulding vertically clear of the bottom moulding being careful not to damage the PCB. Note PCB runners/guide in bottom moulding. Disconnect the 3 OFF battery packs by unplugging on the PCB.
4.
Remove the sealing o-ring from the dome and discard.
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b) Circuit board removal Note that this is only required if the PCB /dome/antenna are damaged. 1.
Using a 7mm socket or nut runner remove the nyloc nut securing the PCB to the antenna.
2.
Slide out PCB noting the guides in the dome moulding. NOTE: Take care not to damage the sea switch contacts on the PCB while it is removed from the moulding.
3.
Remove the silica gel pack from the rear of the circuit board and store the board under anti-static conditions. The antenna can now be pulled out of the dome. Remove and discard the small o-ring.
4.
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c) Battery removal 1. 2. 3.
4. 5.
Note the location and fitting of the frangible tab and switch slider. Using a small posi-driv remove the 2 OFF posi-driv screws retaining the battery clamp. Pull out the battery clamp and battery packs.
Remove foam pad and weight. Retain the weight, discard the foam pad. If the battery is not being replaced check the voltage. Each of the 3 packs must be >9.0V. If any of the 3 battery packs are under voltage then all 3 must be replaced. Take care not to short circuit the battery.
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3.6. Re-assembly Special care is required on the following points: • Ensure that the screw recesses are clean and free of debris. • New o-rings must be fitted • The screws must be tightened to an exact torque. • The EPIRB must undergo a leak test after re-assembly • Expiry date labels must be updated after a battery change. • If the circuit board is replaced, the EPIRB must have its identity reprogrammed. Advise customer that unit may need to be re-registered (and the old unit de-registered).
a) Fit battery 1. Fit metal weight then foam pad in bottom of plastic. 2. Insert battery and battery clamp. Push battery fully down. 3. Fit 2 off no 4x11 pozi pan screws and tighten to 60cNm. It is advisable to start the screws gently in the same thread as before.
b) Fit antenna 1. Slide new small o-ring onto antenna stud. 2. Insert antenna stud into dome moulding.
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c) Refit circuit board 1.
3. 4. 5.
Unseal new silica gel pack. Use double-sided adhesive tape to attach to PCB. Offer circuit board into position. Note that the bracket slides over the stud in the dome and that the PCB fits into guides in the dome plastic. Refit the retaining nut and torque to 60cNm. It is very important to ensure that this is tightened correctly because this is the connection to the antenna for the RF transmissions. Fit new o-ring onto dome moulding. Re-connect battery connectors (3 off). The order/position is not important. Ensure that the magnet is fitted and correctly seated in the switch slider.
6.
Ensure that the switch slider is fitted to the base moulding correctly:
7.
Ensure that the Frangible tab is located as shown:
2.
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Line up PCB with guides in bottom moulding and slide PCB/dome into position.
9.
Note that there will be an approximate 3mm gap between the dome moulding and base moulding prior to fitting the screws. Refit the 3 off M4x12 posi pan screws and washers. Tighten evenly to 60cNm. 10. Carry out a leak test and full functional test (including sea switch and ON test).
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3.7. Leak testing The leak test described here raises the air pressure inside the EPIRB. Check that no air bubbles escape when the EPIRB is submerged in water. Since the EPIRB is buoyant it must held under the water. To avoid activating the unit the sea switch should be disabled by using the magnet (by fitting in a carry safe bracket). .
Gross leak test Use hot water at +60º +5ºC. Cooler water will not raise the air pressure enough. Hotter water will damage the EPIRB. HOT 1. 2. 3. 4. 5. 6.
Remove lanyard. Immerse EPIRB in the hot water. Dislodge ALL trapped air from the screw holes etc. For the next 5 minutes, rotate the EPIRB and check for any escaping bubbles. If there is any sign of water ingress, remove EPIRB quickly. Remove EPIRB from water, wipe thoroughly dry. Note that there will still be water under the outer edge of the dome (inside the outer clear plastic edge but outside the waterproof seal). 7. Refit the lanyard.
Any escape of bubbles must be corrected. Disassemble, rebuild and re-test. A new sealing kit is needed.
Drying times A gross leak may still lead to water inside the EPIRB. If this occurs, then disassemble the EPIRB and dry its component parts in an oven at +40 to +60ºC. Most parts will dry in a few hours, however the battery pack traps water and should be left in the oven for at least 16 hours. The oven is necessary, the battery will not dry out if left at room temperature.
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3.8. Battery change When the battery expiry date is reached the battery needs to be replaced. Ensure that at least 5 years life of the replacement battery before fitting (to comply with IMO regulations). The expiry date is marked on the body of the EPIRB and also on the ident label on the side of the enclosure.
Replacement batteries are supplied as a kit (see spares list). The kit includes a new o-ring and silica gel bag. The kit also includes two new expiry date labels – one for the Autocover (fit supplied expiry label over ident label then place sealing label over to protect) and one for the EPIRB.
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Battery replacement involves complete disassembly of the EPIRB, followed by reassembly, resetting of the PCB battery life and then leak testing to prove the watertight sealing. The procedures elsewhere in this manual should be used as follows: 1. Assess the EPIRB as section 2. 2. Disassemble as per section 3.5. 3. Fit new battery: with new o-rings and silica gel bag. 4. Fit the new expiry date label to the EPIRB body. 5. Re-assemble as section 3.6 (using new parts) 6. Reset PCB 7. Leak test as section 3.7 8. Functional test as section 3.2 9. Message read as per section 3.3 and compare to Identity Label. 10. Fit the second expiry date label over the date on the enclosure side label (if applicable). Fit sealing label over the date label to protect it.
Battery disposal
Hazardous chemicals
Use gloves
Lithium battery packs should be discharged slowly, then disposed of through an approved environmental disposal agent, or in accordance with local regulations. The rate of discharge must not exceed 100mA. It is recommended to discharge through a resistance of a minimum value of 10 ohms per volt of the nominal battery voltage eg a resistor of 90 ohms (2W rating) is satisfactory for a 9V battery. UNDER NO CIRCUMSTANCE MAY THE BATTERY BE SHORT-CIRCUITED. If the battery shows signs of electrolyte leakage, do not attempt to discharge. Refer to the Safety Notices (section 1.4) for advice on correct handling.
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3.9. Reset the Run Time counters on the PCB The Smartfind PCB records the following during the life of the unit: 1. Number of long GPS tests carried out 2. Run time of 406MHz transmissions. 3. Run time of unit including self test. These counters must only be reset after a battery change. The utility is available as a stand alone programme (Smartfind Factory Reset). Note: Carrying out this reset does not alter any of the other programmed information. Procedure: 1. Plug the USB pen into the USB port of the computer. 2. Open ‘Smartfind Factory Reset’ software program. 3. Select the com port. 4. Press ‘Reset Beacon’ 5. Ensure Tx LED flashes on side of pen. 6. Hook the pen into position on the EPIRB. 7. Press TEST button on the EPIRB. 8. The red ‘Reset in progress’ and yellow ‘IR link active’ indicators will light. 9. The EPIRB will emit a number of beeps to indicate reset in progress. 10. The green ‘Factory reset complete’ indicator will light to indicate successful reset.
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3.10. HRU replacement If the EPIRB is in an enclosure marked “Category 1” (automatic, float-free version) it will contain a Hydrostatic Release Unit (HRU). This item has a finite life and a 2 year replacement interval. The HRU expiry date must be checked regularly. The date is marked on the HRU itself and is repeated on the enclosure side label. HRU replacement may be performed by the service provider or by the customer. A replacement HRU kit is available (see spares list, section 6). This includes a new breakable rod with washer and E-clip. We do not currently recommend using any alternative HRUs as these will not be supplied with a new breakable rod, forcing the re-use of the old rod, which is undesirable. The replacement procedure is as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
On the enclosure, remove the R-clip and pull the cover slowly off. Remove the EPIRB and stow it in a dry place. It will activate if wet. Push down the lever arm to take up the force of the spring. Push the HRU back then upwards, out of the slot in the lever arm. When the rear clip disengages slowly release the lever arm. The HRU with its breakable rod can now be lifted free and replaced. Locate the new HRU complete with breakable rod. Mark the HRU with an expiry date 2 years from the date of installation. Slide the HRU into the slot in the lever arm and push lever arm back. Engage rear washer into back plate by pushing back and sliding down. Look under the spring and confirm that the washer is fully engaged. Slide EPIRB into D-shaped foot on lever arm (switch to the right when HRU is at the top) and fold the antenna into its location position. 13. Refit cover by engaging hole over rod and then snapping into place. 14. Refit R-clip in the slot in the top of the rod. 15. On side of enclosure, mark new HRU expiry date, over old date.
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3.11. Programming Programming is the process of transferring information into the EPIRB so that when activated it can correctly identify the vessel it is fitted to. Once activated, this identity is transmitted to the satellite system and rescue services. To ensure a quick rescue response it is important that the identity inside the EPIRB is correct. The identity is not the vessel’s name. Instead it is a country number (eg 232) plus a code associated with the vessel. The code can be: • • •
Serial number (eg 249120 ) MMSI (Mobile Maritime Station Identity) (eg 657000) Radio call sign (eg AM1234)
Note: it is not advisable to use Radio Call sign unless this is the only option permitted by the flag state. For GPS units the GPS position will not be very accurate. The identity is stored in non-volatile memory (EEPROM) on the circuit board. Disconnecting the battery will not affect it, however fitting a new circuit board will.
When to reprogram The EPIRB should be reprogrammed in the following situations: • • • • •
The EPIRB is transferred to a new vessel with a different country code The vessel changes flag state (new country number needed) The MMSI or Call sign has changed A new circuit board is fitted to the EPIRB. Whenever there is any doubt about what is programmed into the EPIRB.
Exceptions EPIRBs flagged to and registered in the USA, Canada, UK and Australia do not need to be re-programmed when transferred to a new vessel with the same flag state. This is because they are programmed with a serialised number. Simply complete another registration form to inform the authorities of the transfer. Plus overwrite the vessel name marked on the EPIRB and its enclosure.
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Programming the EPIRB It is recommended that the latest programming utility, EPROG5 – McMurdo part number 82-951A (McM branded) must be used with the USB pen 82-950A. A personal computer (PC) with the Windows XP/2000 operating system or later is required. The EPROG5 software includes a disk-based handbook giving full instructions for the process. These instructions are not repeated here. Service agents are expected to have a programming kit.
IMPORTANT The following things must be done when an EPIRB is re-programmed: 1. Verify correct programming using a message reader. See section 3.3. 2. Print a new registration form (at the PC) and pass it to the EPIRB owner. 3. If applicable, fit new identity labels to the EPIRB and its enclosure. Remember to transfer the HRU expiry date. EPIRB service manual
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4. FAULT FINDING Test Switch
Battery Connectors
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GPS antenna
Sea contact
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Strobe LED
Buzzer
Silica Gel bag
Sea Contact
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5. REPAIR PROCEDURES Repair policy for this EPIRB is repair by replacement of major sub-assemblies. Component level diagnosis and repair is not supported. The PCB can be inspected for dry joints. The principal repair activity is the replacement of the circuit board. Full instructions for this can be found in section 3.5 Disassembly and 3.7 Reassembly. Other than this, repair is limited to replacing those parts of the EPIRB which have suffered mechanical wear and tear. Spare parts for these purposes are listed in section 6.
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6. SPARES The following items are available as spare parts/accessories: Item
Part number
Variants
Contents
HRU kit USB Pen EPROG5 Battery kit Antenna Kit
82-962-001A 82-951A 92-950A 82-970A 82-974A
McMurdo All McMurdo McMurdo All
Includes Rod and e-clip/washer.
Sealing kit
82-971A
All
GPS PCB
82-972A
G5
Non-GPS PCB
82-9723A
E5
Frangible tab/switch kit
82-997
All
E5 Label kit G5 Label kit Top dome
82-978A 82-981A 82-890-004
McMurdo McMurdo All
Lanyard Manual Bracket Auto Housing
82-923 82-891 82-892
All All McMurdo
User Manual
82-810-001
McMurdo
EPIRB service manual
Includes labels and seals Includes antenna, antenna o-ring and main o-ring. Main o-ring, Antenna o-ring and securing screws. Includes PCB, antenna o-ring and main o-ring. Includes PCB, antenna o-ring and main o-ring. Includes switch slider, magnet, frangible tab and main o-ring For EPIRB and Auto housing For EPIRB and Auto housing Fitted with reflective labels and Test button
Will also need label kit. Does not include HRU. Available form website.
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APPENDIX 1 : SPECIFICATION 406 MHz Transmitter
121.5 MHz Homer
GPS Receiver (Smartfind Plus only)
Strobe light
Battery
Environment
Operating frequency Power output Modulation Operating frequency Power output Modulation
406.028 MHz + 1 kHz 5 W typical Phase (16K0GID) 121.5 MHz +3.5 kHz 50 mW radiated typical Swept tone AM (3K20A3X)
Centre frequency
1.57542 GHz
Sensitivity Satellites tracked Type Light output Flash rate Type Operating life Shelf life
-175 dBW minimum 12 max Two high intensity LEDs 0.75 cd minimum 23 flashes per minute Lithium manganese dioxide 48 hours minimum 5 years typical in service -20 °C to +55 °C (-4° F to +131° F) -30 °C to +70 °C (-22° F to +163° F) 4 metres max. (13 feet) 770 grams (1.7 lb) 21 cm (8.2 inches) 18 cm (7 inches) Cospas-Sarsat T.001/T.007 IEC 61097-2 Marine Equipment Directive USCG/FCC approved FCC ID : KLS-XX-X IEC 61097-2 A.662(16); A.694(17); A.810(19); A.814(19)
Operating temperature Storage temperature
Physical
Approvals
Automatic release depth Weight Height of body Length of antenna Satellite system Europe USA Worldwide Meets IMO regulations
This device complies with the GMDSS provisions of part 80 of the FCC rules.
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APPENDIX 2 : IMO RECOMMENDATIONS At the time of writing the regulations relating to the maintenance of EPIRBs are: IMO MSC/Circ 1039 Guidelines for Shore-based Maintenance of satellite EPIRBs.Dated 28 May 2002 IMO MSC/Circ 1040 Guidelines on Annual Testing of 406MHZ satellite EPIRBs. Dated 28 May 2002 Further details on how to comply with the current regulations are available from McMurdo website or Customer Service. These are detailed in procedure 82-049-001 Guidelines for Shore Based Maintenance.
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McMurdo Limited Silver Point Airport Service Road Portsmouth PO3 5PB United Kingdom Phone: Fax:
+44 (0)23 9262 3900 +44 (0)23 9262 3998
Email: [email protected] Website: www.mcmurdo.co.uk
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Table of Contents 1.
Introduction ..........................................................................................................3 1.1. Scope..............................................................................................................3 1.2. Applicability .....................................................................................................3 1.3. Servicing equipment .......................................................................................4 1.4. Safety notices .................................................................................................5 1.5. False alarms ...................................................................................................7 2. Assessment ..........................................................................................................9 2.1. Maintenance tasks..........................................................................................9 2.2. Routine testing ................................................................................................9 2.3. Assessment ..................................................................................................10 3. Maintenance procedures...................................................................................13 3.1. Inspection......................................................................................................13 3.2. Functional test...............................................................................................15 3.3. Message read ...............................................................................................17 3.4. Internal inspection.........................................................................................18 3.5. Disassembly..................................................................................................19 3.6. Re-assembly .................................................................................................22 3.7. Leak testing...................................................................................................25 3.8. Battery change..............................................................................................26 3.9. Reset the Run Time counters on the PCB ...................................................28 3.10. HRU replacement......................................................................................29 3.11. Programming.............................................................................................30 4. Fault finding........................................................................................................32 5. Repair procedures .............................................................................................35 6. Spares .................................................................................................................36 Appendix 1 : Specification .......................................................................................37 Appendix 2 : IMO recommendations.......................................................................38
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. EPIRB service manual
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1. INTRODUCTION The Emergency Position Indicating Radio Beacon (EPIRB) is a device used to alert search and rescue services in the event of an emergency. It activates via a sea water switch whilst floating in the sea. The EPIRB contains the following three functions: 406MHz transmitter
A powerful 5 Watt transmission is encoded with either a unique serial number or the vessel’s call sign / MMSI. The signal is relayed via satellite to the rescue centre.
121.5MHz transmitter
A low power transmission is amplitude modulated with a swept audio tone and acts as a homing beacon. When the rescue services get close this allows them to direction find on the signal.
Flashing light (strobe)
A bright light flashes every 2.6 seconds as a visual aid during the last stage of rescue.
GPS receiver (optional)
The module receives and decodes the Global Positioning System signals from a satellite network and computes the position of the EPIRB.
The vessels flag state and the vessel identity or serial number is programmed into the EPIRB as part of the 406MHz transmission, thus making the EPIRB unique. Transferring an EPIRB to another vessel either involves re-programming, or reregistration.
1.1. Scope This manual provides the instructions to enable routine and emergency servicing of the EPIRB equipment listed below. This manual represents the original equipment manufacturer’s (OEM) service documentation applicable to these products.
1.2. Applicability This manual applies to the following 406MHz EPIRB equipment: • • • • • •
McMurdo G5 McMurdo E5 Sailor SGE406-II Sailor SE406-II Simrad EG50 Simrad EP50
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1.3. Servicing equipment The following tools and equipment is required to carry out the servicing detailed in this procedure. Equipment: Message reader Leak testing equipment Static-safe work area with operator wrist strap Multimeter with voltage and resistance scales Programming kit : 82-950A Light pen 82-951A EPROG5 (McMurdo variant) Bar magnet or manual bracket with incorporated magnet Shorting link for sea switches Battery discharge load (made on-site as required) Handtools: Calibrated torque driver (0.1 – 1Nm) with attachments: 7mm A/F socket (M4) Small cross-headed screwdriver Large cross-headed screwdriver
Antistatic precautions The electronics section of the EPIRB is sensitive to electrostatic discharge (ESD) which can cause immediate or hidden long term damage. It is important that the PCB is 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 information 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
IPA
Hazard identification Explosive risk, corrosive fumes, fire, biological hazard Bright light Physiological hazard
Irritation, highly flammable
Precautions Handle appropriately, avoid contact Avoid staring at light Avoid close or prolonged exposure. Do not touch the antenna during 406MHz transmissions Avoid contact, ventilate well
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. 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 strobe lights fitted to EPIRBs produce intense flashes of light. No damage is likely to be caused by intermittent exposure, but prolonged exposure should be avoided.
Radio frequency radiation An EPIRB 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; however, it is advisable to avoid touching the antenna of a transmitting EPIRB.
Radio frequency radiation
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.
Read the manufacturer's instructions before using any chemical agent.
Wear goggles
EPIRB service manual
Wear overalls
Wash hands
Wear gloves
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1.5. False alarms Every care must be taken to avoid the generation of false alarms. Modern EPIRBs are activated by sea switches. It is not uncommon for these to activate in rough seas or heavy rain because the EPIRB is not fitted or badly fitted in its mounting bracket. The mounting bracket incorporates a magnet to disable the sea switch. However, if the EPIRB is wrongly fitted the magnet fails to disable the sea switch, so heavy weather may activate the EPIRB. To prevent this, simply ensure that the EPIRB is correctly fitted. For test purposes the EPIRB may be operated in the following ways without generating a false alarm: 1. Self test mode (but avoid repetitive self tests) 2. Live mode for less than 50 seconds (after 50s a live transmission is made) 3. Live mode in a screened enclosure If for any reason the EPIRB is activated outside a screened enclosure (other than as a self test) for more than 50 seconds, it must be assumed that a false alarm has been generated. If this occurs: 1. Deactivate the EPIRB (see below). 2. 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 EPIRB and if possible give the EPIRB ID.
De-activating a live EPIRB Remove the EPIRB from any water and dry the outside. Wait about 8 seconds for the unit to de-activate automatically. If it fails to deactivate ensure that the activation switch is fully off (slide to right). If the EPIRB continues to transmit, it may have 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: 1. Cut off the antenna. 2. Place EPIRB in a metal enclosure, or wrap in metal foil. 3. Leave for three days until the battery is exhausted. If it is absolutely necessary to fully disable the EPIRB (by unplugging the battery) then please see the relevant section of this manual.
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2. ASSESSMENT 2.1. Maintenance tasks Service providers are reminded that it is their responsibility to ensure that the procedures herein are followed, that only McMurdo approved parts are fitted, and that good common practice is observed. False alarms caused by inadvertent activation must be avoided. We recommend that EPIRB testing is only done in self-test mode, where possible, to avoid false alarms. The functions which can be performed by service providers are: • • • • • • • • •
Routine testing Reprogramming Message reading and verification Power measurement Battery replacement Battery life/GPS test reset Leak testing HRU replacement 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. An EPIRB fitted to a GMDSS compliant vessel is recommended to undergo an inspection at yearly intervals and shore based maintenance every 5 years (maximum). To carry out shore based maintenance requires a certification by the manufacturer of the EPIRB. Whatever the reason for the return 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. Included in the user handbook are full details on: Installation Emergency procedure GPS operation test LED operation Therefore these items are not repeated in this manual.
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2.3. Assessment Every EPIRB 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
Fault found
Battery change
Disassemble
Reprogram
Disassemble
Program Print forms & labels Mark HRU date
Internal inspection
Internal inspection
Fault find
Fit battery Mark Dates
Repair
Reassemble
Reassemble
Reset EPIRB
Leak test
Functional test Message read
RETURN
If the EPIRB is opened for any reason, it must be fitted with a new sealing kit.
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 EPIRB and the reason for return (as 'Customer comments'). It is essential to record the identity details from the EPIRB rear label, 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. Procedures for the rest of the form are detailed in section 3. Opening the EPIRB for internal inspection is only required if a problem is found.
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EPIRB ASSESSMENT
Ref No
Customer
Vessel
Type
Man. Serial No
Flag
Call sign/MMSI
ID
Category
Date
Battery expiry date
-
MMSI Call sign
Auto/Manual
Serial
Customer comments
Warranty claim
YES/NO
INSPECTION Manual bracket Magnet present Clip functional
Auto bracket
EPIRB
Cover intact Lever arm operates Magnet present
Tamper intact Plastic acceptable Antenna acceptable Lanyard OK
HRU date
Comments
FUNCTIONAL TEST Sea Switch
Self test
OFF with magnet in 8s Does not activate with magnet
LED on
ON within 3 seconds
Live mode
Buzzer Strobe 3 flashes
LEDs/buzzer on Strobe consistent Switches off
GPS Test
Pass
Comments
MESSAGE READ ID OK 406 frequency OK
MMSI/Call sign/Serial no
Country Man Serial No
EPIRB No
Auto/Man
Comments Required
INTERNAL INSPECTION
Water ingress
Battery OK
PCB corrosion Switch fault
PCB fault Plastic damage
Battery voltage
(optional)
________________V
Comments
New Parts Battery kit Sealing kit Antenna Lens dome Body PCB Assy Label kit F/F label kit
EPIRB service manual
Conclusions
Assessed by
Signed
Date
FINAL LEAK TEST
Pass/Fail
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3. MAINTENANCE PROCEDURES 3.1. Inspection Manual bracket If this has been returned, it should be checked as follows: Magnet
Confirm magnet is still potted into bracket and is not rusting
Release clip
Check for correct and smooth operation. R-clip should engage.
Carry safe
carry safe section should disengage from main bracket.
Automatic bracket (enclosure) If this has been returned, check it as follows: Cover intact
Ensure offset weight is secure. Check cover retaining pin is present and attached to cover. Confirm identity label on side agrees with rear of EPIRB.
Lever arm
Check magnet present. Release HRU (press down and slide upward) Confirm lever arm moves freely and is secure.
HRU expiry date
Side of HRU should be marked with expiry date. Confirm date is acceptable. If less than 3 months left, recommend a new HRU to customer Confirm HRU expiry date is marked on cover side label.
Press lever arm down and refit the HRU. Ensure washer engages (section 3.10).
EPIRB inspection Note that the EPIRB is designed to allow water to circulate around the outer edge of the dome (inside the outer clear plastic edge but outside the waterproof seal), consequently a volume of water in this area is of no consequence. Tamper seal
Check tamper cover/frangible tab is intact and holding switch to right. If tab is damaged or is non-standard in any respect, battery state must be considered suspect. Contact customer to confirm any history of EPIRB activation.
Battery expiry
If there is less than 6 months left to run, contact customer and recommend battery replacement.
Lanyard
Lanyard should be neatly wound onto bobbin. Rewind if required. End of lanyard shall be firmly attached to hole in rear of EPIRB. Bobbin should clip into rear of EPIRB and remain in place.
Sea Switch
Check that the sea contacts are clean and free from paint or grease.
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Plastic damage
Check plastic body for signs of cracking or wear. Check clear lens dome for cracking, especially around screws.
Water ingress
Check if water is visible inside the lens dome or on the PCB.
Antenna damage
If covering is worn to expose steel inside, replace antenna. Antenna should not show signs of being creased at any time.
Identity
Ensure that the Identity information is clear – replace (using programming facility) if necessary.
If the EPIRB or its mounting needs cleaning then this should be done using warm soapy water and a damp (not wet) cloth. Do not use strong detergents or solvents.
Do not paint the EPIRB or its mounting Do not clean with detergents or solvents During vessel cleansing or painting remove the EPIRB and its mounting.
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3.2. Functional test Self test 1. 2.
3. 4.
Press the TEST button until the red LED lights indicating that the self test is running, then release the button. The EPIRB will test its internal components and then make test transmissions at 121.5 and 406 MHz whilst monitoring the transmitter output. If all tests are successful, the buzzer will sound and the red LED and white strobe LED will flash together a number of times. If any test is unsuccessful, nothing will flash and the red LED will go out.
Operation of this test for the Smartfind Plus is identical, except that the green LED will also flash. The number of times the LEDs flash is an indication of the accumulated time the battery has been in use – as long as the strobe flashes at least once then the unit has passed self test. Accumulated Battery Use (hours) 0 to 4 5 to 6 More than 6
Number of flashes/beeps 3 2 1
However as expected battery use per year is only 32 minutes (12 Self tests and 2 off GPS tests) – it is recommended that any unit which has a reduced number of LED flashes should have the battery replaced in order to ensure that the unit will operate for 48 hours in an emergency. Note: The 121.5MHz transmission made during self test is unmodulated. Therefore it will not be picked up by the ARG5410 message readers or by a air band radio receiver. The self test inherently checks the 121.5 and 406 power as part of the test. However if the 121.5MHz must be checked then a Spectrum Analyser or the BT100A EPIRB tester will be required to record the transmission.
Sea switch 1. 2. 3. 4. 5. 6. 7.
Short-circuit the sea switch contacts The red LED should light within 3 seconds and the strobe flash Remove the short circuit The red LED should go out within 8 seconds Place unit into manual bracket or apply magnet to disable the sea switch. Short-circuit the sea switch contacts again The unit should not activate.
The unit must not be allowed to activate for more than 50 seconds to avoid a live transmission. If the red LED starts to flash, you have made a live transmission. EPIRB service manual
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Live test The live test detailed here is for use if a screened enclosure is not available. It is advised that all live testing should be carried out in a screened enclosure. 1.
Use a probe to push back the switch arm and then slide the switch to the ON position.
2. 3.
Ensure that the red LED comes on. Confirm the strobe flashes regularly every few seconds, the green (if fitted) and red LEDs lights and the buzzer sounds. Return the switch to the OFF position to switch the EPIRB off.
4.
This must be done within 50 seconds to avoid a live transmission. If the red LED starts to flash, you have made a live transmission.
GPS operation test The Smartfind Plus (G5) variant has a utility to allow the GPS to be tested. The procedure for testing is included in the user manual and so will not be repeated here. NOTE: The green LED (indicating successful test) only lights at the end of the test while the buzzer/strobe are flashing.
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3.3. Message read To comply with SBM and annual maintenance the service provider must verify the EPIRB 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 EPIRB On the EPIRB press the TEST button After about 4 seconds the Reader should then beep and report DECODING MESSAGE followed by S’TEST OK 5. The Reader will revert to its Menu. Select VIEW mode 6. Use ← → keys to view the decoded 406MHz message content 7. Confirm the frequency was within 406.020 – 406.030 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).
8. Confirm the 15 digit ID agrees with EPIRB rear identity label UIN This proves the 406MHz transmitter is modulating correctly and the EPIRB is programmed with the correct identity. If the ARG5410 is not used then another facility for message decoding must be provided (other message readers).
9. 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
Will not be heard with Smartfind product.
Frequency
If outside limits, repeat self test a number of times. (Provides 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. Move location of EPIRB/reader. Also note that an exhausted reader battery causes bad frames.
Normal mode It is possible to message read in live mode provided the EPIRB is in a screened enclosure. In this case the Reader reports NORMAL OK and the first 3 bytes of the full hex message are FF FE 2F… instead of the usual FF FE D0… for self test mode.
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3.4. Internal inspection Internal inspection is important both for diagnosing faults and for detecting possible faults early. Internal inspection is required under the following conditions: • • • • •
A fault has been observed and needs to be diagnosed If there is any indication of water inside the EPIRB Any salt deposit or corrosion is visible inside Signs of any cracking of the plastic parts Any time the EPIRB is opened for other reasons
Sections 3.5 and 3.6 detail how to disassemble the EPIRB and then re-assemble it. These sections should be followed, but using the notes below as guidance on what to look for during the disassembly process.
Prior to opening EPIRB • •
Inspect lens and body for signs of levering with screwdrivers Inspect antenna for sharp bends, which indicate the EPIRB has been dropped.
With dome removed •
If there is a pungent smell, then suspect that one of the Lithium battery packs have leaked. See section 1.4 for advice. Wear rubber gloves. Damaged lithium batteries may be unstable and pose a serious safety hazard. Leakage usually damages circuit boards, so it is often necessary to scrap the EPIRB without further investigation.
•
If the EPIRB has an electrical fault, make measurements on the battery.
•
Check Sea switch contacts internally.
•
Check circuit board for white salt deposits, dull grey corrosion or wetness. If any corrosion is evident the PCB should be replaced.
•
Check plastic parts, especially screw positions, for signs of cracking.
•
Check condition of EMC coating inside body. Green patches mean water ingress.
With battery removed •
Check condition of weight. Green deposits mean water was present
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3.5. Disassembly EPIRB disassembly should be done under static safe work condition (section 1.3.).
a) Dome moulding removal 1.
Invert unit and using large posi-driv screwdriver remove 3 off screws and washers.
2.
3.
Carefully pull the dome moulding vertically clear of the bottom moulding being careful not to damage the PCB. Note PCB runners/guide in bottom moulding. Disconnect the 3 OFF battery packs by unplugging on the PCB.
4.
Remove the sealing o-ring from the dome and discard.
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b) Circuit board removal Note that this is only required if the PCB /dome/antenna are damaged. 1.
Using a 7mm socket or nut runner remove the nyloc nut securing the PCB to the antenna.
2.
Slide out PCB noting the guides in the dome moulding. NOTE: Take care not to damage the sea switch contacts on the PCB while it is removed from the moulding.
3.
Remove the silica gel pack from the rear of the circuit board and store the board under anti-static conditions. The antenna can now be pulled out of the dome. Remove and discard the small o-ring.
4.
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c) Battery removal 1. 2. 3.
4. 5.
Note the location and fitting of the frangible tab and switch slider. Using a small posi-driv remove the 2 OFF posi-driv screws retaining the battery clamp. Pull out the battery clamp and battery packs.
Remove foam pad and weight. Retain the weight, discard the foam pad. If the battery is not being replaced check the voltage. Each of the 3 packs must be >9.0V. If any of the 3 battery packs are under voltage then all 3 must be replaced. Take care not to short circuit the battery.
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3.6. Re-assembly Special care is required on the following points: • Ensure that the screw recesses are clean and free of debris. • New o-rings must be fitted • The screws must be tightened to an exact torque. • The EPIRB must undergo a leak test after re-assembly • Expiry date labels must be updated after a battery change. • If the circuit board is replaced, the EPIRB must have its identity reprogrammed. Advise customer that unit may need to be re-registered (and the old unit de-registered).
a) Fit battery 1. Fit metal weight then foam pad in bottom of plastic. 2. Insert battery and battery clamp. Push battery fully down. 3. Fit 2 off no 4x11 pozi pan screws and tighten to 60cNm. It is advisable to start the screws gently in the same thread as before.
b) Fit antenna 1. Slide new small o-ring onto antenna stud. 2. Insert antenna stud into dome moulding.
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c) Refit circuit board 1.
3. 4. 5.
Unseal new silica gel pack. Use double-sided adhesive tape to attach to PCB. Offer circuit board into position. Note that the bracket slides over the stud in the dome and that the PCB fits into guides in the dome plastic. Refit the retaining nut and torque to 60cNm. It is very important to ensure that this is tightened correctly because this is the connection to the antenna for the RF transmissions. Fit new o-ring onto dome moulding. Re-connect battery connectors (3 off). The order/position is not important. Ensure that the magnet is fitted and correctly seated in the switch slider.
6.
Ensure that the switch slider is fitted to the base moulding correctly:
7.
Ensure that the Frangible tab is located as shown:
2.
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Line up PCB with guides in bottom moulding and slide PCB/dome into position.
9.
Note that there will be an approximate 3mm gap between the dome moulding and base moulding prior to fitting the screws. Refit the 3 off M4x12 posi pan screws and washers. Tighten evenly to 60cNm. 10. Carry out a leak test and full functional test (including sea switch and ON test).
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3.7. Leak testing The leak test described here raises the air pressure inside the EPIRB. Check that no air bubbles escape when the EPIRB is submerged in water. Since the EPIRB is buoyant it must held under the water. To avoid activating the unit the sea switch should be disabled by using the magnet (by fitting in a carry safe bracket). .
Gross leak test Use hot water at +60º +5ºC. Cooler water will not raise the air pressure enough. Hotter water will damage the EPIRB. HOT 1. 2. 3. 4. 5. 6.
Remove lanyard. Immerse EPIRB in the hot water. Dislodge ALL trapped air from the screw holes etc. For the next 5 minutes, rotate the EPIRB and check for any escaping bubbles. If there is any sign of water ingress, remove EPIRB quickly. Remove EPIRB from water, wipe thoroughly dry. Note that there will still be water under the outer edge of the dome (inside the outer clear plastic edge but outside the waterproof seal). 7. Refit the lanyard.
Any escape of bubbles must be corrected. Disassemble, rebuild and re-test. A new sealing kit is needed.
Drying times A gross leak may still lead to water inside the EPIRB. If this occurs, then disassemble the EPIRB and dry its component parts in an oven at +40 to +60ºC. Most parts will dry in a few hours, however the battery pack traps water and should be left in the oven for at least 16 hours. The oven is necessary, the battery will not dry out if left at room temperature.
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3.8. Battery change When the battery expiry date is reached the battery needs to be replaced. Ensure that at least 5 years life of the replacement battery before fitting (to comply with IMO regulations). The expiry date is marked on the body of the EPIRB and also on the ident label on the side of the enclosure.
Replacement batteries are supplied as a kit (see spares list). The kit includes a new o-ring and silica gel bag. The kit also includes two new expiry date labels – one for the Autocover (fit supplied expiry label over ident label then place sealing label over to protect) and one for the EPIRB.
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Battery replacement involves complete disassembly of the EPIRB, followed by reassembly, resetting of the PCB battery life and then leak testing to prove the watertight sealing. The procedures elsewhere in this manual should be used as follows: 1. Assess the EPIRB as section 2. 2. Disassemble as per section 3.5. 3. Fit new battery: with new o-rings and silica gel bag. 4. Fit the new expiry date label to the EPIRB body. 5. Re-assemble as section 3.6 (using new parts) 6. Reset PCB 7. Leak test as section 3.7 8. Functional test as section 3.2 9. Message read as per section 3.3 and compare to Identity Label. 10. Fit the second expiry date label over the date on the enclosure side label (if applicable). Fit sealing label over the date label to protect it.
Battery disposal
Hazardous chemicals
Use gloves
Lithium battery packs should be discharged slowly, then disposed of through an approved environmental disposal agent, or in accordance with local regulations. The rate of discharge must not exceed 100mA. It is recommended to discharge through a resistance of a minimum value of 10 ohms per volt of the nominal battery voltage eg a resistor of 90 ohms (2W rating) is satisfactory for a 9V battery. UNDER NO CIRCUMSTANCE MAY THE BATTERY BE SHORT-CIRCUITED. If the battery shows signs of electrolyte leakage, do not attempt to discharge. Refer to the Safety Notices (section 1.4) for advice on correct handling.
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3.9. Reset the Run Time counters on the PCB The Smartfind PCB records the following during the life of the unit: 1. Number of long GPS tests carried out 2. Run time of 406MHz transmissions. 3. Run time of unit including self test. These counters must only be reset after a battery change. The utility is available as a stand alone programme (Smartfind Factory Reset). Note: Carrying out this reset does not alter any of the other programmed information. Procedure: 1. Plug the USB pen into the USB port of the computer. 2. Open ‘Smartfind Factory Reset’ software program. 3. Select the com port. 4. Press ‘Reset Beacon’ 5. Ensure Tx LED flashes on side of pen. 6. Hook the pen into position on the EPIRB. 7. Press TEST button on the EPIRB. 8. The red ‘Reset in progress’ and yellow ‘IR link active’ indicators will light. 9. The EPIRB will emit a number of beeps to indicate reset in progress. 10. The green ‘Factory reset complete’ indicator will light to indicate successful reset.
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3.10. HRU replacement If the EPIRB is in an enclosure marked “Category 1” (automatic, float-free version) it will contain a Hydrostatic Release Unit (HRU). This item has a finite life and a 2 year replacement interval. The HRU expiry date must be checked regularly. The date is marked on the HRU itself and is repeated on the enclosure side label. HRU replacement may be performed by the service provider or by the customer. A replacement HRU kit is available (see spares list, section 6). This includes a new breakable rod with washer and E-clip. We do not currently recommend using any alternative HRUs as these will not be supplied with a new breakable rod, forcing the re-use of the old rod, which is undesirable. The replacement procedure is as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
On the enclosure, remove the R-clip and pull the cover slowly off. Remove the EPIRB and stow it in a dry place. It will activate if wet. Push down the lever arm to take up the force of the spring. Push the HRU back then upwards, out of the slot in the lever arm. When the rear clip disengages slowly release the lever arm. The HRU with its breakable rod can now be lifted free and replaced. Locate the new HRU complete with breakable rod. Mark the HRU with an expiry date 2 years from the date of installation. Slide the HRU into the slot in the lever arm and push lever arm back. Engage rear washer into back plate by pushing back and sliding down. Look under the spring and confirm that the washer is fully engaged. Slide EPIRB into D-shaped foot on lever arm (switch to the right when HRU is at the top) and fold the antenna into its location position. 13. Refit cover by engaging hole over rod and then snapping into place. 14. Refit R-clip in the slot in the top of the rod. 15. On side of enclosure, mark new HRU expiry date, over old date.
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3.11. Programming Programming is the process of transferring information into the EPIRB so that when activated it can correctly identify the vessel it is fitted to. Once activated, this identity is transmitted to the satellite system and rescue services. To ensure a quick rescue response it is important that the identity inside the EPIRB is correct. The identity is not the vessel’s name. Instead it is a country number (eg 232) plus a code associated with the vessel. The code can be: • • •
Serial number (eg 249120 ) MMSI (Mobile Maritime Station Identity) (eg 657000) Radio call sign (eg AM1234)
Note: it is not advisable to use Radio Call sign unless this is the only option permitted by the flag state. For GPS units the GPS position will not be very accurate. The identity is stored in non-volatile memory (EEPROM) on the circuit board. Disconnecting the battery will not affect it, however fitting a new circuit board will.
When to reprogram The EPIRB should be reprogrammed in the following situations: • • • • •
The EPIRB is transferred to a new vessel with a different country code The vessel changes flag state (new country number needed) The MMSI or Call sign has changed A new circuit board is fitted to the EPIRB. Whenever there is any doubt about what is programmed into the EPIRB.
Exceptions EPIRBs flagged to and registered in the USA, Canada, UK and Australia do not need to be re-programmed when transferred to a new vessel with the same flag state. This is because they are programmed with a serialised number. Simply complete another registration form to inform the authorities of the transfer. Plus overwrite the vessel name marked on the EPIRB and its enclosure.
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Programming the EPIRB It is recommended that the latest programming utility, EPROG5 – McMurdo part number 82-951A (McM branded) must be used with the USB pen 82-950A. A personal computer (PC) with the Windows XP/2000 operating system or later is required. The EPROG5 software includes a disk-based handbook giving full instructions for the process. These instructions are not repeated here. Service agents are expected to have a programming kit.
IMPORTANT The following things must be done when an EPIRB is re-programmed: 1. Verify correct programming using a message reader. See section 3.3. 2. Print a new registration form (at the PC) and pass it to the EPIRB owner. 3. If applicable, fit new identity labels to the EPIRB and its enclosure. Remember to transfer the HRU expiry date. EPIRB service manual
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4. FAULT FINDING Test Switch
Battery Connectors
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GPS antenna
Sea contact
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Strobe LED
Buzzer
Silica Gel bag
Sea Contact
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5. REPAIR PROCEDURES Repair policy for this EPIRB is repair by replacement of major sub-assemblies. Component level diagnosis and repair is not supported. The PCB can be inspected for dry joints. The principal repair activity is the replacement of the circuit board. Full instructions for this can be found in section 3.5 Disassembly and 3.7 Reassembly. Other than this, repair is limited to replacing those parts of the EPIRB which have suffered mechanical wear and tear. Spare parts for these purposes are listed in section 6.
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6. SPARES The following items are available as spare parts/accessories: Item
Part number
Variants
Contents
HRU kit USB Pen EPROG5 Battery kit Antenna Kit
82-962-001A 82-951A 92-950A 82-970A 82-974A
McMurdo All McMurdo McMurdo All
Includes Rod and e-clip/washer.
Sealing kit
82-971A
All
GPS PCB
82-972A
G5
Non-GPS PCB
82-9723A
E5
Frangible tab/switch kit
82-997
All
E5 Label kit G5 Label kit Top dome
82-978A 82-981A 82-890-004
McMurdo McMurdo All
Lanyard Manual Bracket Auto Housing
82-923 82-891 82-892
All All McMurdo
User Manual
82-810-001
McMurdo
EPIRB service manual
Includes labels and seals Includes antenna, antenna o-ring and main o-ring. Main o-ring, Antenna o-ring and securing screws. Includes PCB, antenna o-ring and main o-ring. Includes PCB, antenna o-ring and main o-ring. Includes switch slider, magnet, frangible tab and main o-ring For EPIRB and Auto housing For EPIRB and Auto housing Fitted with reflective labels and Test button
Will also need label kit. Does not include HRU. Available form website.
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APPENDIX 1 : SPECIFICATION 406 MHz Transmitter
121.5 MHz Homer
GPS Receiver (Smartfind Plus only)
Strobe light
Battery
Environment
Operating frequency Power output Modulation Operating frequency Power output Modulation
406.028 MHz + 1 kHz 5 W typical Phase (16K0GID) 121.5 MHz +3.5 kHz 50 mW radiated typical Swept tone AM (3K20A3X)
Centre frequency
1.57542 GHz
Sensitivity Satellites tracked Type Light output Flash rate Type Operating life Shelf life
-175 dBW minimum 12 max Two high intensity LEDs 0.75 cd minimum 23 flashes per minute Lithium manganese dioxide 48 hours minimum 5 years typical in service -20 °C to +55 °C (-4° F to +131° F) -30 °C to +70 °C (-22° F to +163° F) 4 metres max. (13 feet) 770 grams (1.7 lb) 21 cm (8.2 inches) 18 cm (7 inches) Cospas-Sarsat T.001/T.007 IEC 61097-2 Marine Equipment Directive USCG/FCC approved FCC ID : KLS-XX-X IEC 61097-2 A.662(16); A.694(17); A.810(19); A.814(19)
Operating temperature Storage temperature
Physical
Approvals
Automatic release depth Weight Height of body Length of antenna Satellite system Europe USA Worldwide Meets IMO regulations
This device complies with the GMDSS provisions of part 80 of the FCC rules.
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APPENDIX 2 : IMO RECOMMENDATIONS At the time of writing the regulations relating to the maintenance of EPIRBs are: IMO MSC/Circ 1039 Guidelines for Shore-based Maintenance of satellite EPIRBs.Dated 28 May 2002 IMO MSC/Circ 1040 Guidelines on Annual Testing of 406MHZ satellite EPIRBs. Dated 28 May 2002 Further details on how to comply with the current regulations are available from McMurdo website or Customer Service. These are detailed in procedure 82-049-001 Guidelines for Shore Based Maintenance.
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McMurdo Limited Silver Point Airport Service Road Portsmouth PO3 5PB United Kingdom Phone: Fax:
+44 (0)23 9262 3900 +44 (0)23 9262 3998
Email: [email protected] Website: www.mcmurdo.co.uk
82-992 Issue 1
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