C1 S-VDR

Service Manual

Commercial in confidence

36-261

Table of Contents
1.

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

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

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

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

36-001-001A Firewire 6GB

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

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S-VDR EPIRB in mount

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1.3 Servicing equipment

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

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

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1.4 Safety notices

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

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

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

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

Lithium batteries

Hazardous chemicals

Wear gloves

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

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

Radio frequency radiation

Radio frequency radiation

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

General precautions for chemical agents (adhesives, greases, IPA)

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

Wear goggles

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Wear overalls

Wash hands

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Wear gloves

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1.5 False alarms

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

1.6 Deactivating the EPIRB

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

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

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

2.2 Routine testing

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

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

RECEIPT

HRU change

Fit HRU
Mark dates

Assessment
Inspect
Functional test
Message read

Reprogram

Fault found

Battery
change

Disassemble

Disassemble

Program
Print forms
Complete labels

Internal inspection

Internal inspection

Fault find

Fit battery
Mark dates

Repair
Reassemble
Leak test

Functional test
Message read

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

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

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S-VDR ASSESSMENT

Ref No

Date

Customer

Vessel

Type

Man. Serial No

Battery
expiry date

Country

Call sign/MMSI

MMSI
Call sign

UIN

Category

Auto/Manual

Serial

Customer comments

Warranty claim

INSPECTION

YES/NO

Auto bracket

Magnet present
Strap/buckle intact

HRU date

Plastic condition
Cables OK
BIM

FFC

Integrity seal intact

Plastic OK
Antenna OK
Lanyard OK

Comments

FUNCTIONAL TEST
Live mode

Sea Switch

Self test

Deactivates


Does not activate with magnet

Red LED on

Activates

3 strobe flashes
LED

Green

Strobe activates
within 8 s

Comments

MESSAGE READ
121 sweep heard
406 frequency OK

ID

MMSI/Call sign/Serial no

Country
Man Serial No

EPIRB No

Auto/Man

Comments

INTERNAL INSPECTION
Water ingress
Plastic damage

PCB corrosion
Switch fault

Required

PCB fault

Battery voltage
volts

Comments

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

Conclusions

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Assessed by

Signed

Date

FINAL LEAK TEST

Pass/Fail

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

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

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

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

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

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

Self test
1.
2.
3.
4.

Press and hold the TEST button.

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

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

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

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3.3 Message read

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

On the Reader select RECV mode

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

5.
6.
7.
8.

The Reader should beep and report STEST OK

The Reader will revert to its Menu. Select VIEW mode
Use keys to view the decoded 406MHz message content
Confirm the frequency was within 406.020 406.030

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

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

9. Confirm the 15 digit ID agrees with FFC identity label UIN

This proves the 406MHz transmitter is modulating correctly and the EPIRB is
programmed with the correct vessel identity. If the ARG5410 is not used then another
facility for message decoding must be provided (other message readers).

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

Q
11:25
Mesg#11 STEST OK
ID: 9D0D071D3B00013
406.0257 MHz
PASS

Common problems
Audio tone

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

Frequency

If outside limits, repeat the self test two or three times in

rapid succession to provide a warm up time. Repeat test.

Bad frame

This error message occurs if the Reader fails to

synchronize.
This occurs approx. 10% of the time. Repeat test
multiple times. If EPIRB achieves <30% bad frames then
it is acceptable.
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 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 FFC
Any salt deposit or corrosion is visible inside
Signs of any cracking of the plastic parts
Any time the FFC 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

Carry out inspection as per section 3.1

With dome and gasket removed

If there is a pungent smell, then suspect that the Lithium battery pack has 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.

Check top of circuit board for white salt deposits, dull grey corrosion or wetness.
If any corrosion is evident the FFC should be completely disassembled.

Check plastic parts, especially screw positions, for signs of cracking and for
possible leakage paths.

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3.5 Disassembly
Open the FFC
1. Use a Posi driv scewdriver to remove all 10 main body seal bolts.
2. The FFC should now open when the top cone, DSM and bottom cones are
pulled gently apart.
Note: If the cones will not come apart, there is probably a partial vacuum
inside the EPIRB. Do not lever the cones apart as this will cause damage. Use
an 11mm A/F socket to loosen the TEST switch boot. A slight hiss will be
heard as the vacuum releases. When it stops, re-tighten the TEST switch
boot. Pull the cones apart.

3. Gently lift the top cone up taking great care not to damage the Reed switch
PCB which extends into the DSM

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4. . The battery and sea switch leads will limit the cone separation; unplug them
as shown and feed them back through the DSM.

5. Remove the large rubber gaskets (one white and one black) which form the
main body seals.
Bottom cone (battery)
The bottom cone contains the battery and the sea switch contacts. There are
no serviceable parts. If a fault develops or the battery expiry date is reached
then the unit should be replaced.
Remove the PCB section
Observe anti-static precautions. Unplug the two switches ON and TEST.
Remove the seven board mounting screws and withdraw the board, complete
with antenna from the top cone. Take care not to loose the foam pads locating
the antenna PCB in the top cone.
The PCB (EPIRB section) (36-030B) contains 3 PCBs:
S-VDR EPIRB PCB (36-040B)
S-VDR Antenna PCB (36-050B)
Reed switch PCB (36-052B)
Separating the 3 PCBs
The PCBs are joined by the electrical connectors (push fit) and the wedge.
The wedge is very tight and it may be necessary to heat the PCB up to 50C to
soften the plastic to ease removal.
Removing the switches.
The 2 off switches can be removed by undoing the switch boot using an 11mm
driver. The switches are located in the plastic and cannot rotate.
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Data storage module

The DSM should only be dismantled if the unit has been returned after activation or
the data retrieval procedure has failed. Under these circumstances it is necessary to
have access to the individual storage cards. Take a note of the Temperature label: if
it has changed colour (ie reached a temperature of 77C or above) then the
electronics may have been subjected to extreme heat.

1. Remove the 11 off screws retaining the cover.

2. Cut the tie holding the cable in position and remove the white gasket .

3. Remove the 4 off screws retaining the modules and PCB. Pull out the module and
remove the connecting lead to the PCB.

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4. Remove the screws holding modules in place. Remove the storage cards. Note
the position of the drives so that unit can be reassembled correctly.
5. Note that special tools are required to remove the connector from the plastic. The
tool is available from Odu (part no 701-098-002-000-000).
BIM/Bracket Disassembly
1.
2.
3.
4.

Remove the bot retaining the plastic cover onto the bracket.
Remove the plastic cover.
Remove the 4 off screws retaining the cover on the Ethernet/Firewire module.
The module can now be removed by removing the 4 off revelaed screws.

Insert picture

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Exploded view of S-VDR FFC

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3.6 Reassembly
This procedure explains how to re-assemble the FFC from its individual piece parts. If
the FFC has not been fully disassembled, start at the appropriate heading.
Warning: It is mandatory to fit new sealing gaskets whenever the FFC is opened.
Fit switches to top cone
Inspect the sealing surfaces of the top cone for damage and dirt particles which
might affect its ability to seal. If acceptable, proceed as follows.
1. Start with the ON switch assembly. Fit the panel seal small 'O' ring to the
switch mounting bush and locate the switch in the underside of the top cone
between the two small label recesses. (The hole has a polarising lug which
locates against the 'flat' on the switch.) Hold the switch in position and fit the
rubber switch boot with the larger 'O' ring from the upper surface of the top
cone until it is finger tight.
2. Fit the TEST push button switch into the top cone between the two large label
recesses. Use the small 'O' ring to seal the switch mounting bush, and fit the
larger 'O' ring seal supplied with the rubber switch boot on the top surface of
the cone. Leave finger tight at this stage.
3. Offer up PCB from the underside of the top cone until it locates over the two
switches (the PCB acts as a location and tightening aid). Using a 11mm A/F
hex socket, carefully tighten each switch boot to a torque of 0.75Nm. Take
care not to damage the rubber boots. When complete remove the PCB.
Fit PCB into top cone
1. Refit Antenna (ensure lens dome is fitted): Offer up the antenna from the noncomponent side of the PCB and locate it in connector block and through the
aperture in the PCB. Refit the wedge in the direction shown on the PCB. (Hint:
may require the wedge warming up to 50C to allow fitting).

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2. The PCB can now be turned over and located in the top cone. Ensure that the
4 off adhesive washers are still fitted to the outer mounting points. Assembly is
easiest if the top cone is turned over (antenna down) and supported in a
suitable box or container.
3. Ensure that the spring earth contacts on the PCB are not distorted.

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4. Before dropping the PCB into the inverted top cone, rotate the PCB until its 7
mounting holes are aligned with the 7 support pillars in the top cone and
ensure the switch cables are fed through the 2 holes in the PCB. The PCB
should now sit squarely in the top cone. This is important to avoid damage to
the reed switch PCB and the foam pads on the antenna.

5. Secure the PCB in place using 7 off M3 screws, 8mm long with integral locking
washers. These should be tightened to 60cNm. Now fit the two switch cables
into their relevant PCB connectors.

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Reassemble the Data Storage Module

1. If replacing the drives then ensure that drives have been formatted correctly or
remember to format once assembled.
2. Assemble the bracket to the PCB using one screw tightened to 85cNm.
3. Refit the drives to the PCB in the order previously noted. Secure using 4 off
screws tightened to 60cNm for each drive.

4. Place a tie wrap into the plastic and refit the module. Secure using 4 off self
tapping screws tightened to 85cNm (note these screws should be hand started
into the exsting threads).
5. Reconnect the cable to the PCB and refit the ferrite if removed.
6. Route the cables as shown and tighten the tie wrap.

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7. New desiccant bags should be fixed using double sided tape to the top of the
unit prior to refitting the cover.

8. Fit the gasket noting orientation (as this is a secondary seal a new gasket is
not essential).
9. Secure the cover noting orientation with the LEDs. The 13 off screws are self
tapping screws and should be hand started in the same threads to 85cNm.
10. Using a DVM check for continuity (less than 0.5 ohms per square) between
pillars, lid and RF coating.
11. Ensure that 2 off EMI strips are fitted to the base.

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12. Fit 2 off new desiccant bags must be fixed using double sided tape to the
cover.

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Final Assembly
1. The bottom cone assembly has a potted-in battery. The battery expiry label
fitted to the outside of the bottom cone must not have expired.
2. Inspect the sealing surfaces of the bottom cone for damage and dirt particles
which might affect its ability to seal. If acceptable, support the cone in a
suitable box or container so that it stands upright.
3. Fit a new main sealing gasket (white). Place the gasket in the groove in the
bottom cone and rotate it until it lines up with the 10 bolt holes.
4. Feed the cables through the DSM and place the DSM onto the bottom cone
lining up correctly. The DSM aligns with both the bottom cone and the top
cone:

5. Fit the black gasket to the top of the DSM.

6. Connect the battery lead and the sea switch lead to the top cone PCB.
7. Fit the top cone lined as above. Warning: Do not twist the top cone on the
DSM as the reed switch may get damaged.
8. Loosely fit the 10 off M4x45 screws and washers. Tighten the screws to
85cNm in a diametrically opposed sequence to avoid stressing the plastic.
9. Refit the cable, lanyard (if fitted) and the cable protector when fitting to the
bracket.

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Leak test
Perform a leak test to prove the integrity of the seals.
Refit the lanyard
1. The orange lanyard is nominally 21m long and should already be neatly
coiled. If necessary, re-coil the lanyard.
2. Cut off the old knots and remove the DO NOT TIE label. Retain the plastic
switch cover. Uncoil approx. 0.5m of fresh lanyard from one end of the coiled
lanyard.
3. Stand the FFC (without release mount) in a suitable container or box for
support. Thread the lanyard through the lanyard flange, leaving about 15cm of
lanyard between the flange and the coiled lanyard. Tie a bowline knot to allow
adjustment.

To be rewitten

This completes the assembly of the EPIRB

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3.7 Leak testing

WARNING: It is mandatory to perform a leak test on any occasion when the FFC is
opened.
The principle of leak testing is to cause the internal pressure of the FFC to increase
above atmospheric pressure, and to check that no air bubbles escape when the FFC
is submerged in liquid. The FFC is designed to float, so it must be constrained to
ensure it stays submerged. The container used for the test must be at least 28cm in
diameter and 28cm deep.
CAUTION: Submerging the FFC in a conductive liquid (eg tap water) will cause it to
activate unless it is disabled by attaching a magnet to it. Use a magnet and attach it
to the rim of the FFC as shown in .2 Sea switch test

Gross leak test

CAUTION: This test uses hot water. Take appropriate protection
measures.
Hot

1.
2.

3.
4.

5.
6.

Fit the magnet, as described above. Remove the lanyard if fitted.

Immerse the EPIRB in hot water: the ideal temperature is 60 +5C; cooler
water will not cause a sufficient rise in temperature, hotter water may
damage the EPIRB.
Dislodge all trapped air from the sealing screw holes, the switch areas and
the retaining area.
For the next five minutes, while keeping the EPIRB submerged check for
the escape of bubbles, particularly from the gasket and the sealing
screws.
Remove the EPIRB from the water, wipe dry the sea switches then dry the
EPIRB thoroughly before removing the magnet.
Refit the lanyard if appropriate.

Any escape of bubbles must be corrected by disassembling the EPIRB, replacing or

refitting the source of the leak, and retesting.

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3.8 Battery replacement

Use the Assessment flow chart (Section 2.3) and Assessment form when carrying out
a Battery change.
The battery is permanently fitted in the bottom cone of the FFC; replacement is thus
a matter of replacing the bottom cone complete.
The battery pack contains 2 separate sets of cells both identical.
The open-circuit voltage of a satisfactory battery should be above 9.0V Batteries
reading less than 9V on open-circuit must be replaced.
To change the battery, disassemble the FFC as described in section 3.5 Fit the new
cone by following the appropriate instructions in section 3.6
As per the flow chart: carry out a leak test, functional test and message read.

3.9 Disposal of batteries

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 120 ohms (2W rating) is satisfactory for a 12V 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 Warnings (section Error! Reference source not found.) for advice on correct
handling.

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3.10

HRU Replacement Kit

IMPORTANT: Read these instructions thoroughly before attempting to change the

HRU. If in doubt seek expert assistance.
WARNING: Ensure power is switched off at the DCU and at the 24 V power supply
before starting any work around the Capsule
Dismount capsule from bracket
Remove and retain the thumbscrews which retain the connector protective shield,
then remove the shield. Grip the connector sleeve and withdraw the connector.
Remove the R-clip from the latch. Hold the capsule with one hand and open the
latch. Release the retaining strap and remove the capsule. THE CAPSULE IS NOW
ARMED AND WILL TRANSMIT IF IT BECOMES WET. ENSURE IT STAYS DRY
UNTIL IT IS REPLACED IN THE BRACKET.
Remove HRU & cable assembly
Remove bracket cover retaining bolt (arrowed)
then remove the bracket cover.

Remove the cover from the Bracket Interface

Module (BIM). Note that there are variants of these
interfaces; however, the wiring to the capsule (right
connector) is identical on all interfaces. DO NOT
DISTURB THE WIRING TO THE LEFT
CONNECTOR.
TAKE CARE WHEN HANDLING THE CABLE; IT
WILL BE RE-USED WHEN FITTING THE NEW
HRU.

Remove and retain the cable clamps from the right

cable. Disconnect the cable from the right
connector, slacken the gland and remove the cable.

Carefully remove the cable from the breakable bolt

and retain it for re-use. Remove and discard the
split pin, the breakable bolt and the HRU.

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Re-assembly of strap & cable

The expiry date must be marked on the HRU. The HRU has a 2 year in-service life
which starts as soon as it is exposed to a marine environment, hence the 2 year
period starts at installation; it is the responsibility of the installer to mark this date
during installation. A date 2 years into the future should be marked on the HRU body
by cutting out the corresponding dates on its label, as shown on the leaflet enclosed
with the HRU kit.

Connector end
of cable

Fully open

Assemble the HRU and breakable bolt, then thread the cable through the bolt in the
direction shown; finally fit the strap, ensuring that the split pin is completely open to
retain the shackle.
WARNING: The assembly must be orientated as shown in the illustrations.
Fit the HRU and strap to the bracket, as
shown, and thread the free end of the
cable through the hole in the bracket.

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Connecting the Capsule data cable

Slacken the right hand cable gland and thread the cable through it. Connect the
cable to the right BIM connector, following the table below.
BIM to FFC
J2
White
Black
screen
Orange
Blue
Red
Green

1
& 2

+V
0V

3
4
5
6

RxRx+
TxTx+

Refit the cable clamps and tighten the gland.

Assembling the bracket
Replace the lid of the junction box and ensure that it is correctly fitted. Check that all
cable glands are tight.
When fitting the cover, ensure that it is fully seated and that it overlaps completely
the bottom metal plate. Finally, fit and tighten the retaining bolt.

Plastic edge flush with

or proud of metal

Note: Do not leave excess cable between the BIM and the HRU. The illustration
shows the recommended maximum size of loop. Equally, it is important to leave
sufficient loop to avoid straining the cable the cable should not be taut at any point.
Refitting the capsule
Fit the Capsule to the bracket, making sure that the locating lug engages correctly,
and retain it by attaching the strap to the hook and closing the latch. Check that the
strap is tight and holds the Capsule firmly; if it is not, tighten it by adjusting the strap
at the buckle. (As a guide, it should just be possible to close the latch; if the latch
closes easily, the strap should be adjusted.). Fit the R-clip to the latch, as shown in
the following pictures.

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WARNING: THE S-VDR

CAPSULE MUST ALWAYS BE
MOUNTED SUCH THAT THE
MOULDED LOCATION FEATURE
ON THE LOWER SECTION OF
THE CAPSULE LOCATES
AGAINST THE BRACKET
CORRECTLY

Locating channel
in Capsule

Locating
lug on
bracket

Finally, fit the data connector. Ensure that the connector is pushed fully home and
that it locks in position. Replace the protective cover and tighten the thumbscrews.

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3.11 Programming
Programming is the process of transferring information into the EPIRB section 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 vessels 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)

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.

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.
Simply complete another registration form to inform the authorities of the transfer.
Plus overwrite the vessel name if marked on the EPIRB and its enclosure.

3.12 Data Recovery

This section to be advised.

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Programming the EPIRB

Programming the EPIRB requires the Programming Kit and a personal computer
(PC). The kit contains all parts required, together with a handbook giving full
instructions for the process.
Accordingly, the full instructions will not be repeated here.
To programme the FFC hold the pen against the programming point and press the
TEST switch. If the data is accepted the red LED will flash. If the data is not accepted
the unit will go into self test mode.

It is essential that new labels are fitted to identify the re-programmed EPIRB; ensure
that the customer receives a new registration form.

Verifying programming
Programming should be checked using a message reader.

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4. FAULT FINDING
4.1 Confirming PCB faults
If it is suspected that the FFC has an electrical fault, then it is likely that the problem
is in the electronics PCB.
Before replacing any parts, the fault must be confirmed by first eliminating the
battery, the switches and the antenna as causes.

1. Disassemble the EPIRB by following steps 1 to 3 in section 3.5

2. Inspect the wiring between the board and the two user switches. Check for
sound joints at each wire end and check that no strands of wire are protruding
from the joints.
3. If a sea-switch fault is suspected, then verify that the two sea-switch contacts
are electrically sound by connecting the sea-switch connector to an ohmmeter.
With the contacts open the reading should exceed 5M ohms and with the
contacts shorted (with a screwdriver) the reading should drop to below 20K
ohm.
4. Fit a known good battery and check the fault again. If the fault disappears then
the battery was either flat or faulty.
5. If the fault is related to either the 406MHz or 121.5MHz transmission, then it is
possibly the antenna that is defective, although an antenna fault is likely to
cause a reduction of RF power rather than a complete lack of signal. Verifying
the antenna involves removing it, inspecting it for damage and then
substituting a known good antenna.
a) Observe anti-static precautions. Unplug the two switches on the board.
Remove the seven board mounting screws and withdraw the board from
the top cone. Remove the antenna as described in this manual
b) Inspect the antenna for damage. Compare it to a new one for
distortions/differences. Check for dry joints.
c) To verify whether the antenna was at fault, fit a known good antenna to the
board, re-fit the board into the top cone (using all seven screws to ensure a
good ground plane connection) and confirm whether the fault is still
present.
6. Check the reed switch works by checking with a magnet.
7. If the problem persists, then the fault in the electronics board is confirmed.

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5. REPAIR PROCEDURES
It is not permitted to attempt to service the PCB. If a fault is suspected, it must be
returned to the manufacturer for repair. Other parts may be replaced as necessary.
The disassembly and assembly instructions (sections 3.5 and 3.6) should be used as
appropriate.

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6. SPARES
Branded items
The following items carry identification markings identifying the supplier:
Reference
36-149-XXXB
82-962-xxxA

Description
Battery kit (including gaskets, screws and desi bags).
HRU Kit

36-020-XXXB
36-200-XXXB
36-100-XXXB
36-060-XXXB
36-070-XXXB

Programming Kit
Top cone assy including PCBs
Mounting Bracker
FFC
DSM
Data storage assembly

Please specify brand when ordering.

Additional spare parts

Reference
2D-260-004
36-040
36-050
36-052
36-075
36-076
36-085
36-322
36-087
36-099
36-124
36-146
36-147
36-222B
36-226B
36-235
80-7009
82-209
99-145
To be advised
To be advised
To be advised
36-031
36-232
36-230B
36-214
36-115
99-118
36-207

Description
Gasket (white) battery
EPIRB PCB
Reed switch PCB
Antenna PCB
DSM gasket
DSM Internal cable
PCB Wedge
Foam strip (for Antenna)
DSM to bracket cable assembly
Mounting bracket kit
Gasket (black) Top cone
Connector Protector
Lanyard
Activation (ON/Test) switch assembly
BIM Firewire module
BIM Ethernet module
Desiccant bag
Magnet
Thumb screw
Sealing kit (including gaskets, screws and desi bags).
Flash drive 2GB Ethernet
Flash drive 2GB Firewire
Switch cap assy
Bracket cover assy
R clip assy
Mounting strap assy
M6x30 Machine screw
M3x16 screw
M16 cable gland

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7. APPENDIX 1: SPECIFICATION
DRU section
Supply voltage
Power consumption
Interface
Protocol
Data transfer rate
Number of drives
Drive capacity

12/24 V nominal (10.7 to 32.0 V )

<3 W
10/100BASE-T Ethernet
SMB
3.4 MB/s maximum sustained rate
One (two available)
2 Gbytes (Other capacities up to 128 Gbytes available)

EPIRB section
General
Approved to
Complies with
Operating temperature range
Storage temperature range
Operational life
Battery type
Battery expiry
Electrical
406.028 MHz transmitter
Frequency
Output power
Data encoding
Modulation
Transmission time
Repetition period
121.5 MHz transmitter
Frequency
Output power
Transmit duty cycle
Modulation format
Modulation frequency sweep
Modulation duty cycle
Sweep repetition rate
Sweep direction
GPS receiver/engine
Centre frequency
Received signal sensitivity
Satellites tracked (max)
Transmit antenna
Type
Characteristics
Receive antenna
Type
Characteristics
External interfaces
Programming interface
Manual activation
Self test/Manual deactivation

COSPAS-SARSAT T.007 Class 1

EN 60945
-20 C to +55 C (Class 2)
-50 C to +70 C
168 hours minimum at 20 C
9 V lithium manganese dioxide
6 years from date of manufacture

406.028 MHz +1 kHz

5 W+2 dB
Bi-phase L
Phase modulation; 1.1 rads +0.1 rads
520 ms +1%
50 secs +2.5 secs
121.5 MHz +3 kHz
50 mW +3 dB PERP
100%
3K20A3X (2K00A2A during Morse V Tx)
1250 Hz to 322 Hz
(fixed 1 kHz tone during Morse V Tx)
41% +5%
3 Hz +1 Hz
Programmable UP or DOWN
Band L1 1.57542 GHz
-175 dBW minimum
12
Vertical PCB monopole
Vertically polarised, omni-directional
Ceramic dielectric patch
RH circular polarised, gain +3 dBi nominal
IR link to PC serial port
Push-to-make switch with tamper cover
Push-to-make switch

Visual strobe (nominal values)

23 FPM , 0.75 Cd over 75% of horizontal plane

Physical characteristics
Weight
Height (capsule)
Diameter (capsule)
Buoyancy
Sealing

3.5 kg (Capsule); 2.7 kg (Bracket)

481 mm
267 mm max
Buoyant
Waterproof to 10 m immersion

Communications
Time to first transmission
Typical time to alert
Position accuracy

2 minutes
LEOSAR: 90 minutes*
120 m typical

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APPENDIX 2 : IMO RECOMMENDATIONS

IMO Guidelines for annual maintenance (Circ 1040) and Shore based maintenance (Circ 1039) apply
to this product.
They are not reproduced here as they may change please obtain by other methods.

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McMurdo Limited
Silver Point Airport Service Road Portsmouth PO3 5PB United Kingdom
Telephone:
Int + 44 (0)23 9262 3900
Fax:
Int + 44 (0)23 9262 3824
www.mcmurdo.co.uk
36-261 Iss1

CHEMRING GROUP PLC