Techtest. Limited. Crash Position Indicator System. Type Maintenance Manual. Techtest. L imited

Transcription

1 Techtest Limited Crash Position Indicator System Type Maintenance Manual Techtest L imited

2 Preface This manual is a controlled document, and as such is subject to amendment. It is in the interest of the user to register this manual with Techtest Ltd. to ensure receipt of any amendments. Any unsatisfactory feature of this manual should be addressed to: Customer Support Techtest Limited Street Court Kingsland Leominster Herefordshire HR6 9QA U.K. Tel No. +44 (0) Fax No. +44 (0) sales@hr-smith.com

3 Amendments Record No. Changed By Date C/N Reference 1 M.Thompson 20/05/03 TT M.Thompson 07/10/03 TT M. Thompson 19/12/03 TT M. Thompson 24/03/04 TT G. Probert 25/10/04 TT G. Probert TT G. Probert TT G. Probert TT1419 Issue Number Issue Date Document Number C/N Number HRS TT 1419

4 Contents Section Title Page No. Preface Amendment Record Contents 1. System Description 1 2. Maintenance Guidelines General Required Equipment System Testing 2 3. Maintenance Procedure Crash Position Indicator Beacon Cleaning Fitting and Removal Detaching Beacon Re Attaching Beacon Scheduled Maintenance Battery On Condition Maintenance CPI Beacon Sealing Gasket Beacon Release Unit Scheduled Maintenance Actuator On Condition Maintenance Sealing Gasket System Interface Unit Series Scheduled Maintenance Battery On Condition Maintenance Sealing Gasket Cockpit Control Panel Series Water activated Switch Series Confi guration Unit Post Maintenance Testing General Maintenance LRU Maintenance Built in Test Failure 8 5 Illustrated Parts Catalogue Cockpit Control Unit Confi guration Unit System Interface Unit Water Activated Switch Beacon Release Unit CPI Beacon 14

5 1. System Description The Techtest Crash Position Indicator (CPI) System is a primary radio location aid to alert Search and Rescue authorities and assist location in the event of an aircraft distress situation. The system is designed for installation in helicopters and fixed wing aircraft and features a locator beacon containing the transmitter and antenna. The beacon, which can be both manually and automatically activated, is deployed from the aircraft in the event of a crash, providing full emergency frequency operation at MHz and MHz. The CPI system consists of the Beacon, a Beacon Release Unit, System Interface Unit, Cockpit Control Panel, Water Activated Switch and an Aircraft Identification Device (A schematic, detailing the constituent parts of the system is shown at Figure 1). An Installation drawing of each Line Replaceable Unit can be found in section 5, Illustrated Parts Catalogue Cockpit Control Panel 2.Aircraft ID Configuration Unit 3. System Interface Unit 4.Beacon Release Unit 5. Water Activated Switch 6.Beacon Figure 1 1

6 2. Maintenance Guidelines In order to maintain a safe working environment, it is recommended that the following guidelines are adhered to when working on the CPI system. 2.1 General All maintenance work, as detailed in this publication, should be performed by suitably qualified personnel. In the absence of suitably qualified personnel, the equipment can be returned to Techtest for any maintenance work. Before engaging in any maintenance work it is essential that the CPI system is isolated, and powered down by switching the ARM switch on the SIU (Part No ) to OFF. The system should be left for at least 5 seconds to fully discharge before beginning any work. NOTE: The system has a re-chargeable back-up battery. If the battery is charged, removing the circuit breaker on the aircraft, without setting the ARM Switch to OFF will not deactivate the system. If at any time the CPI Beacon Part No is removed from the Beacon Release Unit Part No , the Protective Cover Plate (Part No. 0881) should be attached to the Beacon Release Unit, and remain in place until the CPI Beacon is re attached. 2.2 Required Equipment If maintenance is to be performed by the end user, or a third party, the following test equipment is recommended to confi rm the system is fully functional. Equipment Techtest Part No Portable SARSAT Beacon Test Set Programming Test Set (optional) CPI Programming Adaptor (optional) CPI Programming Adaptor - USB port (optional) USB Beacon Activation Testset Beacon Firing Unit System Testing The CPI system has a Built in Test which can be used to assess the system s integrity (Section 4). If there is a fault in the system it will also indicate the location so the correct maintenance work can be performed (Section 4.3) 2

7 3. Maintenance Procedure Before engaging in any maintenance work it is essential that the CPI system is isolated, and powered down by switching the ARM switch on the SIU (Part No ) to OFF, the system should be left for at least 5 seconds to fully discharge before beginning any work. Important - This system has a re-chargeable back-up battery. If the battery is charged, removing the circuit breaker on the aircraft will not de-activate the system. 3.1 Crash Position Indicator Beacon: Cleaning At regular service intervals, and upon removal for maintenance, the beacon should be cleaned to remove surface contamination due to exhaust gas residue. This is to prevent the likelihood of degradation of the surface lacquer or underlying ABS moulding. The recomended cleaning agent is methylated spirit Fitting and Removal Detaching Beacon Before any maintenance work can be carried out on the Beacon, it must be removed from the Beacon Release Unit as directed below P/N Remove the M6 Fixing Bolt (Part No. 0862) M6 Spring Washer (Part No. NC ) and Lock Plate (Part No. 0863) which sit in the recess on the front of the CPI Beacon. Once removed the beacon will not be fixed to the release unit, care should be taken to support the Beacon to prevent it from falling. The Beacon can be carefully drawn off the release unit. P/N MOD 1 & 2 Remove the M6 Fixing Bolt (Part No. 0862/1), and Lock Plate (Part No. 0863) which sit in the recess on the front of the CPI Beacon. Once removed the beacon will not be fixed to the release unit, care should be taken to support the Beacon to prevent it from falling. The Beacon can be carefully drawn off the release unit The Release Unit Cover (Part No. 0881), should be fi xed to the Release Unit using 2 M5x30 Pan Head screws and should remain in place until the Beacon is to be re attached Reattaching Beacon The Release Unit Cover should be removed from the Release Unit, by removing the 2 M5 Pan head screws Fit the Beacon to the Release Unit, locating the Beacon connector s guide pins in to the Release Unit s fl oating connector. The Beacon can then be pressed into position. 3

8 Whilst the Beacon is supported in place, insert the M6 Fixing Bolt, lubricated with MoS2 or Cu Grease, with the Spring Washer (if applicable) and Lock Plate and torque tighten to lbf-in ( Nm) Inspect the joint between the Release Unit Sealing Gasket and Beacon, ensuring the fit is flush and a good seal is formed Scheduled Maintenance Battery The CPI Beacon has an internal LiS02 battery pack, (Part No. A0936) which must be replaced every 5 years. This interval is dependent on the Beacon having not been deployed or set to transmit at any point during the battery s installed life. If the Beacon has been set to either of these, the battery should be replaced immediately. The BIT (Built in Test) is not regarded as either of these actions. Note: The CPI Beacon battery cannot be replaced by the user. The Beacon must be returned to Techtest Ltd. for battery replacement and recertification On Condition Maintenance CPI Beacon If, at any time, the CPI Beacon is deployed, it should be returned to Techtest for inspection Sealing Gasket Periodic inspections should be made to the Sealing Gasket (Part No ) located between the Beacon s Case and Cover. If there are any noticeable signs of degradation to the gasket that could affect its operating performance, it should be replaced as directed below Remove the Beacon s 12 M4 x 20 Stainless Steel Cap Head socket screws, 12 M4 Shake proof washers and all 3 M4 x 10 Stainless Steel Button Head socket screws from the Case. Carefully separate the case and cover, ensuring none of the affi xed assembly is damaged Replace the damaged Sealing Gasket with (Part No ) Carefully replace the Cover, locating the Case s pillar in the Cover s through hole, ensuring the screw holes of the Gasket, Case and Cover line up, and secure with screws and washers removed in section The screws should be progressively torque tightened to lbf in ( Nm) working in a diagonally opposite tightening pattern. The 3 M4 stainless steel Button Head socket screws should also be tightened to lbf in ( Nm). Note: The 12 retaining screws can relax after a period of time and the torque settings should be checked, and the screws re-tightened if neccessary, to the above setting on every C overhaul. 4

9 3.2 Beacon Release Unit: Should the Beacon Release Unit be removed from the Installed system for shipping, storage etc. the Protective Cover Plate (Part No. 0881) should be affixed, and remain in place until the unit is to be re installed Scheduled Maintenance Actuator The Actuator, contained within the Beacon Release Unit, has an installed life of ten years, or one Deployment fi ring. If the Beacon Release Unit has fi red for any reason, or reached its operating life threshold, it should be returned to Techtest for replacement On Condition Maintenance Sealing Gasket Periodic inspections should be made to the Sealing Gasket, (Part No. 0921) located between the Beacon Release Unit and the CPI Beacon. If there are any noticeable signs of degradation to the gasket that could affect its operating performance, and ability to produce a water tight seal it should be replaced as detailed below Remove the CPI Beacon from its installed location as detailed in section Remove the Sealing Gasket from the edge of the Beacon Release Unit and replace with new part. The BRU s 4 Countersunk mounting screws will have to be loosened to allow the gasket to be released Tighten the 4 screws to lbf in ( Nm) and replace the CPI Beacon as detailed in section System Interface Unit: Series Scheduled Maintenance The SIU contains components with an operational life of 10 years. After 10 years of operation the SIU must be replaced or returned to Techtest Limited for refurbishment Battery The internal battery of the System Interface Unit (Part No. A01011) must be replaced every 5 years, as detailed below Remove the Battery Cover Panel (Part No ) and Gasket (Part No ) by unscrewing the four M3x8 Pan Head Screws The Battery Removal Tool (Part No.0716) supplied with the replacement battery, should be inserted into the slot between the Battery and housing until it clicks into place. The battery can then be drawn out of its housing, and disposed of safely. NOTE: The battery O ring must also be replaced during this process. 5

10 The replacement battery can now be inserted into the housing, and should be pushed into place until it locates with a click The Battery Cover and gasket should be replaced using the screws removed in section On Condition Maintenance Sealing Gasket Periodic inspections should be made to the Sealing Gasket (Part No ) located between the SIU and the battery cover. If there are any noticeable signs of degradation to the gasket that could affect its sealing capabilities, it should be replaced as directed below Unscrew the 4 M3x8 screws on the Battery Cover Panel and remove Replace the Sealing Gasket (Part No ), ensuring all holes through line up The Battery Cover should be replaced, and torque tightened to lbf in ( Nm) using the screws removed in section Cockpit Control Panel: Series This item is not maintainable by the end user, and in the event of failure should be returned to Techtest for repair/ replacement as deemed necessary. 3.5 Water Activated Switch: Series This item is not maintainable by the end user, and in the event of failure should be returned to Techtest for repair/ replacement as deemed necessary. 3.6 Configuration Unit: This item is not maintainable by the end user, and in the event of failure should be returned to Techtest for repair/ replacement as deemed necessary. 6

11 4.0 Post Maintenance Testing 4.1 General Maintenance General maintenance work includes Battery and Gasket Replacement or any work that does not require any LRU s to be detached from the CPI System. This does not include removing the Beacon from the Release Unit. Once any maintenance work has been completed, and units replaced, the following test procedure should be performed The system must be switched to the ARM position on the SIU switch (Figure 2) before testing can be initiated. The Built in Test (BIT) takes place via the cockpit control panel. A Portable SARSAT Beacon Test Set, (Part No ) should be used to take a message reading from the Beacon whilst the BIT is being performed. Consult the Portable SARSAT Beacon Test Set User Manual for operating instructions To test the system, press the Test/Reset button (Figure 3), both the TX/TEST and BEACON GONE indicators will illuminate (Figure 4). The TX/TEST indicators will then flash in synchronisation with a swept tone (Figure 5). Figure 2 Figure 3 Both the indicators will then extinguish (Figure 6), signalling that the system has passed BIT successfully. If the BIT passes, the reading taken by the Portable SARSAT Beacon Test Set should be cross checked against the Aircraft information. If there is a disparity in the information, the Confi guration Unit can be reprogrammed using the Programming Test Set, (Part No ) or CPI Programming Adapter (Part No ). Should the indicators remain illuminated (Figure 7) and six beeps are heard from the cockpit control panel, the BIT has failed. The TEST/RESET button should be pressed (Figure 3), and the BIT re-initiated to overcome possible battery passivation If, after three attempts, the indicators remain illuminated, the BIT has failed. Reference should then be made to section 4.3 Figure 4 Figure 5 Figure 6 It is recommended that testing of the system should be minimised, since testing does use battery capacity. 4.2 LRU Maintenance LRU maintenance includes any work which requires LRU s to be replaced and/or returned to Techtest for repair/ replacement. When the system has been reinstalled it is recommended that its operational performance be verified utilising the System Installation Test Set, (Part No ). Figure 7 Reference should be made to the System Installation Test Set Operating Manual in order to carry out these tests. 7

12 4.3 Built in Test Failure Power-up BIT Fail When the system starts, it attempts to read the distress massage and the g- activation levels for the aircraft from the ID unit. If it fails to read this message both enunciators will illuminate momentarily, and the system will restart and re-attempt to read from the ID box. A persistant fail will characterize itself as the enunciators continually fl ashing at a very slow rate. If the system initializes successfully there will be 2 beeps, and no enunciators will illuminate Diagnostic BIT In the event that the CPI System BIT indicates a FAIL, a diagnostic test should be performed as follows. Switch the System to OFF at the SIU. Switch the SIU to ARM whilst the Test/Reset button is depressed. The system will beep once, signalling test initiation, followed by two swept tones and a beep. There will then be a string of beeps, the number being dependent on the type of fault. The list below can be used to identify the fault. No. Beep Train Beeps 1 SIU Access to Beacon Fail 2 2 SIU Accelerometer SIU Accelerometer SIU Accelerometer Beacon Battery 7 6 Beacon rf Failure 8 7 Beacon Tests Completed 9 Fault No.1 If fault 1 is indicated then the cables between the SIU and beacon should be checked, ensuring they are attached and in good working order. If the fault persists, contact Techtest Limited. Fault No.2,3,4 If any of these are indicated, the SIU is at fault and should be replaced or the system shut down and Techtest Limited Informed. Fault 5 If fault 5 is indicated the Beacon s Battery should be replaced, and the system retested. The BIT may have to be performed up to 3 times to overcome possible battery passivation.if the fault persists, contact Techtest Limited. Fault 6. If fault 6 is indicated the Beacon is at fault and the supplier should be contacted Fault 7 If fault 7 is indicated the system is at fault and the supplier should be contacted. If any of these faults are not immediatly rectifi ed the system should be set to OFF at the SIU, and the Beacon removed from the aircraft (Section 3.1.1) until the system is repaired. 8

13 5. Illustrated Parts Catalogue 9

14 Cockpit Control Unit Series Configuration Unit

15 System Interface Unit Series No. Part No. Qty. Description 1. NA Screw, Pan Head 2. NA Spring Washer 3. NA Washer Battery Cover Gasket 6. A Ni-Cad Battery 11

16 Water Activated Switch Series 12

17 1. Beacon Release Unit No. Part No. Qty. Description Sealing Gasket 13

18 Beacon Beacon MOD 1 & 2 No. Part No. Qty. Description No. Part No. Qty. Description Lock Plate Lock Plate 2. NC M6 Spring Washer 2. N/A 0 M6 Spring Washer Special Bolt /1 1 Special Bolt 14

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