AIS SART S5 Service Manual
Commercial in Confidence Table of Contents 1. Introduction... 3 1.1. Scope... 3 1.2. Applicability... 3 1.3. Product History (up to Apr 2010)... 3 1.4. Servicing equipment... 3 1.5. Antistatic precautions... 3 1.6. Safety notices... 4 2. Assessment... 5 2.1. Maintenance tasks... 5 2.2. Routine testing... 5 2.3. Assessment... 5 3. Maintenance procedures... 7 3.1. Inspection... 7 3.2. Functional test... 7 3.3. Disassembly... 7 3.4. Reassembly...10 3.5. Leak Testing...10 4. Fault finding...11 4.1. Fault location...11 4.2. System Block Diagram...12 4.3. Service Bulletins...12 4.4. Software Release Notes...14 5. Repair procedures...15 6. Spares/ACCESSORIES...16 Appendix 1: Specification...17 Appendix 2: MESSAGE STRUCTURES...18 AIS SART S5 Service Manual Page 1
AIS SART S5 service manual Page 2
1. INTRODUCTION 1.1. Scope This manual provides the instructions to enable routine and emergency servicing of the S5 AIS SART. This manual represents the original equipment manufacturer s (OEM) service documentation applicable to these products. 1.2. Applicability This manual applies to the following equipment: i McMurdo Smartfind S5 AIS SART Part number 92-001-001A i i Kannad Marine Safelink AIS SART Part number 92-001-002A Sailor 5051 Part number 92-001-003A 1.3. Product History (up to Apr 2010) i Apr 2010 New product release 1.4. Servicing equipment The following tools and equipment are required to carry out the servicing detailed in this manual. Equipment: i i AIS receiver Screened box with GPS fixture Hand tools: i i i i Calibrated torque driver with attachments: Small cross-headed screwdriver (No. 1 Pozidrive) Straight blade screwdriver 5mm socket with long extension 1.5. Antistatic precautions The electronics section of the product 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. 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. AIS SART S5 service manual Page 3
1.6. 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 Hazard identification Precautions Lithium battery Explosive risk, corrosive fumes, fire, Handle appropriately, avoid contact biological hazard Radio frequency radiation Physiological hazard Avoid close or prolonged exposure. Do not touch the antenna during transmissions Adhesives Skin irritation, fumes Avoid contact, ventilate well IPA (propanol) Irritation, highly flammable Avoid contact, ventilate well 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 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 Wear overalls Wash hands Wear gloves AIS SART S5 service manual Page 4
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 Orolia ltd approved parts are fitted, and that good practice is observed. The functions which can be performed by service providers are: i i i Routine testing Fault diagnosis Repair 2.2. Routine testing Whatever the reason for the return the AIS SART must be subjected to a full assessment before any other action is taken. The agent has a responsibility to ensure the AIS SART S5 is completely serviceable and is fit for purpose prior to being returned to the customer. Included in the user handbook are full details on: i Installation i Set-up i Operation Therefore these items are not repeated in this manual. 2.3. Assessment Every AIS SART S5 returned for servicing must be fully assessed to determine its operational status. Assessment form The assessment form, shown on the next page, is an essential tool in performing diagnosis. It may also be used to support your customer invoicing and needs to be completed for any warranty return to Orolia ltd AIS SART S5 service manual Page 5
AIS SART S5 ASSESSMENT Ref Date Customer Address Type Battery expiry date: Serial No Vessel name: Customer comments Return to Customer? YES/NO Warranty claim YES/NO INSPECTION/DIAGNOSIS Items Returned Item Condition Main unit Storage case Manual Other (list) DIAGNOSIS FUNCTIONAL TEST Burn-in Functional Test Comments New Parts Fitted Conclusions Upper case Lower case Battery Frangible tab Pole Assembly Lanyard Storage case Assessed by Signed Date Pass Fail AIS SART S5 service manual Page 6
3. MAINTENANCE PROCEDURES 3.1. Inspection 1. Visually inspect the unit for any physical damage and missing parts noting any problems on the assessment form 3.2. Functional test (self test) 1. With the unit in a location where GPS fix can be obtained (i.e. outside with a clear view of the sky or in range of a GPS repeater system), press and hold the TEST button until the red LED illuminates. 2. The red LED will flash quickly to indicate that a self test is in progress 3. The maximum self test duration is 5 minutes, with an average of 1 minute given a good GPS signal 4. A successful test will result in the red LED signalling 3 long flashes 5. Once the self test has completed the AIS SART will switch off automatically If the unit does not complete the above test then the unit is defective and needs further attention. Additionally, if an AIS receiver is available, the unit will, during the self test, make a series of live test transmissions. The test message includes the unique 9 digit ID number for the SART, along with the latitude and longitude of the unit s position. The AIS receiver will normally indicate as a SART TEST. 3.3. Disassembly 1. Remove the pole assembly from the main unit, depress the two buttons to release the end cap from the pole assemble AIS SART S5 service manual Page 7
Take care with the exposed blade which can have sharp edges. Original type (hard) connector Caution Sharp 2. Undo the three body screws Later type (soft) connector AIS SART S5 service manual Page 8
3. Carefully pull the two case halves apart to expose the PCB and battery, carefully withdraw the PCB from the case 4. Unplug the battery from the PCB AIS SART S5 service manual Page 9
3.4. Reassembly 1. Reassembly is a reverse of the disassembly instructions a. The use of silicone grease on the main body O ring is advised to prevent it being displaced during assembly b. Ensure switches on PCB face toward keypad and PCB engages in PCB slots c. Do not refit the pole assembly until after a leak test is performed NB. If the top casing needs to be replaced, then the serial number will need to be written onto the unit with a waterproof marker or label 3.5. Leak Testing Gross leak test Use hot water at +60 C ±5 C (140 F ± 9 F) Cooler water will not raise the air pressure enough. Water above 60º C will damage the AIS SART S5. CAUTION HOT 1. Remove lanyard. 2. Remove the pole, see section 3.3.1 3. Immerse the AIS SART S5 in the hot water. 4. Dislodge ALL trapped air from the screw holes etc. 5. During the next 5 minutes, rotate the AIS SART S5 and check for any escaping bubbles NB. If there is any sign of water ingress (bubbles are seen escaping), quickly remove the AIS SART S5 from the water 6. If no bubbles are observed, remove AIS SART S5 from water and thoroughly dry 7. Refit the pole assembly. Any escape of bubbles must be corrected by Disassembly, rebuild and re-test. A new sealing kit will be required. Drying times A gross leak may still lead to water inside the AIS SART S5. If this occurs, then disassemble the AIS SART S5 and dry its component parts in an oven at +40 C to +60 C. 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, as the battery will not dry out if left at room temperature. Do not exceed this temperature as the battery may explode. CAUTION DO NOT EXCEED 60 C RISK OF EXPLOSION AIS SART S5 service manual Page 10
4. FAULT FINDING 4.1. Fault location Start Tab Broken? Y Replace battery N Replace battery N Self test OK? Replace tab Y Self test OK? Y N Replace Unit Unit OK AIS SART S5 service manual Page 11
4.2. System Block Diagram The AIS-SART consists of a 2W RF transmitter which switches between AIS-A (161.975MHz) and AIS-B (162.025MHz). A block diagram is shown below The transmitter sends out a specified pattern. Every minute, a sequence of eight messages is transmitted; each message is transmitted in a 26ms time slot. Four messages are transmitted on AIS 1 and four on AIS 2. All eight messages are transmitted within a total time frame of 14 seconds. This time frame is defined to maximise the probability that one of the transmissions will coincide with the AIS SART being at the top of a wave, so enhancing the probability of reception. It is only necessary to receive one of the eight messages from time to time to accurately locate the AIS-SART. Any vessel or station which can receive and detect an AIS signal will also detect an AIS-SART. The information transmitted by the AIS-SART provides identification and location. Identification consists of an MMSI ID code, where the first three digits will be 970. The ID code consists of a total of 9 digits and the AIS-SART uses the remaining 6 digits to indicate a manufacturer code (2 digits) in addition to the unit s unique serial number (4 digits). 9 7 0 X X X X X X country code: AIS-SART manufacturer batch code unique serial number The ID code that appears on the AIS receiver and connected equipment will also be visualized on a ships electronic chart, onboard ships with modern integrated installations. An AIS-SART will be shown as a circle with a built-in cross. AIS SART S5 service manual Page 12
4.3. Service Bulletins Service bulletin 59 8/6/10 AIS SART serial numbering The initial production batch of the AIS SART, has the leading three digits of the serial omitted. The serial number is attached to the main body of the unit and should be as below The number is also on the rear of the carry bag. The serial number should be in the form 970xxxxxx, where xxxxxx is the sequential manufacturing number. The affected units do not have the 970 at the front of the number. During both test and live transmissions, this serial number is transmitted as the MMSI number in the message sent and in all cases will include the 970 characters. If you require replacement labels for your stock, or for any units please advise us of the serial numbers of the unit(s) you require them for and they will be supplied free of charge. AIS SART S5 service manual Page 13
4.4. Software Release Notes None Available AIS SART S5 service manual Page 14
5. REPAIR PROCEDURES Repair policy for this product is repair by replacement of major sub-assemblies. Component level diagnosis and repair is not supported. The PCB can be inspected for dry joints etc but component replacement is not possible. If the PCB is damaged, then the AIS SART S5 must be replaced The principal repair activity is the replacement of the battery. Full instructions for this can be found in section 3.0 Disassembly and Reassembly. Other than this, repair is limited to replacing those parts of the AIS SART which have suffered mechanical wear and tear. Spare parts for these purposes are listed in section 6. AIS SART S5 service manual Page 15
6. SPARES/ACCESSORIES The following items are available as spare parts: Part number Description Contents 92-050A Battery kit 92-051A Tamper kit 92-056-001A (McMurdo) 92-056-002A (Kannad) 92-056-003A (Sailor) 92-057-001A (McMurdo) 92-057-002A (Kannad) 92-057-003A (Sailor) 92-058-001A (McMurdo) 92-058-002A (Kannad) 92-058-003A (Sailor) Top casing kit Battery casing kit Label kit Battery w/expiry label Battery foam M3 x 12mm screw (3) O ring Instruction sheet Anti tamper tab M3x12mm screw (3) Top casing Switch label Battery Casing Operation label Tail connector bolt Tail blade Tail O ring M2.5 nyloc nut Operation label Pole height label AIS SART S5 service manual Page 16
The following items are available as accessories: Part number Description Contents 92-054A Lanyard Assembly Lanyard 92-055A Pole kit 92-052-001A (McMurdo) 92-052-002A (Kannad) 92-052-003A (Sailor) Storage case kit Pole End cap Pole connector Label Foam insert Storage bag Foam insert 92-059-001A (McMurdo) 92-059-002A (Kannad) User manual 92-059-003A (Sailor) 92-053A Wall mounting kit Mounting kit APPENDIX 1: SPECIFICATION Please note that the product specification is issued in the user manual for each product. The user manual is delivered with each new product and is also available on our website. Orolia ltd reserves the right to change specifications without notice. AIS SART S5 service manual Page 17
APPENDIX 2: MESSAGE STRUCTURES The AIS SART5 transmits messages in NMEA format on the two AIS frequencies AIS1, 161.975 MHz And AIS2, 162.025 MHz Utilising message types 1 (position report) and 14 (safety related broadcast message) NMEA AIS Message Format Here is a typical NMEA standard AIS message: AIVDM,1,1,,A,14eG;o@034o8sd<L9i:a;WF>062D,0*7D In Order:!AIVDM: The NMEA message type 1 Number of Sentences (some messages need more then one) 1 Sentence Number (1 unless it's a multi-sentence message) The blank is the Sequential Message ID (for multi-sentence messages) A The AIS Channel (A or B) 14eG;... The Encoded AIS Data 0* End of Data 7D NMEA Checksum AIS Data Format The AIS data is in an encoded format, full details can be found in the ITU M.1371-2 standard
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Orolia Ltd Silver Point Airport Service Road Portsmouth PO3 5PB United Kingdom Phone: +44 (0)23 9262 3900 Fax: +44 (0)23 9262 3998 Email: service.mcmurdo@orolia.com Website: www.mcmurdomarine.co.uk 92-259N ISSUE 1