FLIR UltraFORCE 350-HD User manual

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Owner’s Manual
(Operation & Maintenance Manual)
(Note: Picture layout is typical. May vary depending on system configuration)

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Table of Content
1UltraFORCE 350-HD Operation .......................................................... 5
1.1 Scope............................................................................................... 5
1.2 1st Line Maintenance......................................................................... 5
1.3 UltraFORCE 350-HD Operation........................................................ 9
1.4 Controls and functionality................................................................ 13
1.5 Screen Symbology.......................................................................... 41
1.6 Auto Tracker Functionality.............................................................. 45
1.7 Laser Range Finder........................................................................ 49
1.8 Laser Pointer and Illuminator.......................................................... 50
1.9 Inertial Measurement Unit............................................................... 51
1.10 Built in Test.................................................................................. 52
1.11 Storage Considerations................................................................ 54
1.12 Operational Performance Considerations .................................... 54
1.13 Fig 1 Screen Symbology –General ............................................. 58
1.14 Fig 2 Hand Control Unit (Front View) ........................................... 59
1.15 Fig 3 Hand Control Unit (Side View) ............................................ 60
2Maintenance...................................................................................... 61
2.1 Scope............................................................................................. 61
2.2 Reference Documents.................................................................... 61
2.3 Functional Description.................................................................... 61
2.4 Service Levels (Line and Base Maintenance)................................. 62
2.5 Tools and Equipment List ............................................................... 64
2.6 Spare Parts..................................................................................... 66
2.7 Repair and Calibration.................................................................... 67
For Operational Limitations;
See Product Specification SYS11000PS.

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Amendment Record:
Date
Revision
Amendment Details
2012-07-05
NC
First Issue
2013-05-03
A
IMU Menu system updated.
New Function: Matched field-of-view added.
2014-04-10
B
Matched field-of-view function removed.
Function changes due to change of cameras.
2014-06-08
C
Spotter overlay and auto iris functionality changed due to
change of camera.
2014-06-18
D
Added polarity button for Hitachi SC-120R.
2014-06-18
E
Adjusted behavior of Spotter Auto functionality.
2014-12-01
F
(Re-written) Numerous editorial changes and various
clarifications added.
2015-07-15
G
1.2.4, 1.2.5, 2.5.1, 2.5.4: Added clarifications and spare part
numbers for desiccant checks and maintenance.
1.3.3: Added instructions for flying the TCU in an unpowered
state.

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Abbreviations
(Used in this Manual)
CW / CCW
Clockwise / Counterclockwise
DC
Direct Current
FOV
Field Of View
GPS
Global Positioning System
HCU
Hand Control Unit
ICD
Interface Control Document
IMU
Inertial Measurement Unit
IR
Infrared
LI
Laser Illuminator
LOS
Line Of Sight
LP
Laser Pointer
LRF
Laser Range Finder
LRU
Line Replaceable Unit
N/A
Not Applicable
NC
No Change
NFOV
Narrow Field Of View
NUC
Non-Uniformity Correction
NVG
Night Vision Goggles
TCU
Turret Camera Unit
TI
Thermal Imager
WFOV
Wide Field Of View
WoW
Weight On Wheels

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1 UltraFORCE 350-HD Operation
1.1 Scope
General
This document details the methods and procedures used to operate the UltraFORCE
350-HD system, operational level maintenance, and storage considerations.
Audience
The expected audience for this document is trained System Operators and Maintenance
Technicians.
1.2 1st Line Maintenance
1.2.1 Pre-flight check/Daily Inspection
Remove the protective hood. (if present/applicable)
Gently move the turret by hand to ensure free movement in the azimuth and
elevation bearings.
If deemed necessary, clean the TCU according to §1.2.2 and 1.2.3.
Check the humidity indication of the two Desiccator Breathers and the Desiccator
Indicator. (See §1.2.4 for desiccant checks and maintenance)
Carefully place the TCU in STOW position by hand before the power-on procedure
is started.
1.2.2 Cleaning
When the TCU surface requires cleaning, a clean damp cloth with a mild solution of
dishwashing soap should be used. Do not wash the optical windows with the same cloth
as used for the TCU surfaces. The windows should be treated as a separate process in
order to prevent general TCU dirt and grit from damaging the optical surfaces.

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1.2.3 Cleaning the external optical surfaces
Although salt deposits, insects and finger prints etc. rarely cause a noticeable loss of
system performance, many substances may accelerate the deterioration of the optical
coatings on the windows, and should therefore be removed. Use a clean non-abrasive
cloth and clean water with a mild dishwashing soap solution (or equivalent) to clean the
optics.
Apply light pressure and always soak and soften any dirt particles that are difficult to
remove. Always consider your actions and avoid the possibility of scratching the
surfaces. It is especially important to remove fuel and oil deposits from the daylight
window since these fluids refract the light, which may cause an out of focus effect in the
image.

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1.2.4 Desiccant checks and maintenance
The TCU is equipped with two Desiccator Breathers to control the internal environment
and to maintain the components in good condition. The desiccators should be checked
before each mission as a part of the pre-flight check.
NOTE: If the TCU recently has been operated in a high humidity environment, the desiccants may require
up to 4 hours for stabilizing and giving a correct humidity reading.
The TCU also has a built in Desiccator Indicator providing a visual indication of the
moisture content. A blue reading is an indication that the internal atmosphere is dry, while
a pink reading indicates that high levels of moisture are present.
A partial blue and pink reading is an indication that a moderate level of moisture is
present, which is considered normal and acceptable.
If just the two Desiccator Breathers (not the Indicator) are indicating that moisture is
present, then just the Breathers needs to be dried using FLIR Systems Polytech AB
GEN00035 Desiccator Dryer Kit or P990024 Refill Kit for Breathers, or replaced with new
P990002 Desiccant Breather(s).
If the Desiccator Indicator indicates moisture (>40%), the drying procedure (purging)
needs to be performed. (See § 1.2.5 and 1.8.8)
After purging, all three (3) desiccators should be replaced or dried using the GEN00035
Desiccator Dryer Kit / P990024 Refill Kit for Breathers.
Desiccator Indicator (1 ea) P/N: P990001
Indicates pink if moisture level is >40%
Desiccator Breathers (2 ea) P/N: P990002
Indicates pink at two moisture levels; 15% and 30%
(Refill Kit P/N: P990024)

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1.2.5 Drying procedure (Purging)
If the level of moisture within the TCU is too high and the Desiccator Indicator is
completely pink, then action should be taken to dry the TCU using a supply of low
pressure dry nitrogen.
A Purging Kit (GEN00035) is available as an option for this purpose.
For detailed instructions regarding the purging process;
See the Maintenance section of this manual. (§ 2.5.2)

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1.3 UltraFORCE 350-HD Operation
1.3.1 Power-on (start-up) procedure:
Ensure that the TCU has mechanical freedom of movement and that no
interference from surrounding objects/obstructions is present.
Ensure that the TCU is placed in STOW position before the system is powered
on.
Ensure that a stable DC power supply is available.
NOTE: Do not power-on the TCU during aircraft engine start-up.
Ensure that a monitor is correctly connected and powered up.
Power-on the system using the HCU. (see § 1.4.1)
Perform a Joystick calibration, as described in § 1.4.7.
Null any Azimuth and Elevation drift, as described in § 1.4.12 and 1.4.13.
NOTE: This action should be performed when the system has warmed up in order to achieve
the best result.
The system will start-up and initialize according to the conditions defined below:
NOTE: The thermal imager will need a cool down period of approx. 7 min before an
image is displayed. The TI display is showing INIT during this period (See § 1.5.6)
Avoid to power-off the TCU during the initialization phase.
Feature
Condition after initialization
Initial Position
Last CAGE setting (or STOW if STOW
switch is selected)
Joystick Sense
Push forward for negative elevation
Auto Tracker Mode
Standby
Selected Sensor
TV camera
TV FOV
Fully wide
TV E-Zoom
No Electronic Zoom selected
TV Iris & Gain
Automatic
TV Focus
Autofocus
TV Freeze
Live image
TV IR Cut off filter
In
TV White Balance
Automatic
TI FOV
Wide
TI E-Zoom
No Electronic Zoom selected
TI Level & Span
Automatic
TI Polarity
White hot
TI Freeze
Live image
TI DDE
DDE off

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Feature
Condition after initialization
Spotter FOV
Full Narrow
Spotter E-Zoom
N/A
Spotter Iris & Gain
Automatic
Spotter Gamma
Off
1.3.2 Power-off (shut down) procedure:
The system can be powered off from any mode, at any time, without damaging the
system. However, avoid to power-off the system during the initialization phase.
From an operational point of view, it is highly recommended to select STOW prior to
powering off, as the STOW position is important for the protection of the optical windows
during aircraft take-off and landing.
1.3.3 Flying the TCU in an unpowered state
The TCU must be in STOW position if the system is to be flown in an unpowered state
(e.g. during ferry flight.)
NOTE: The TCU can be moved to STOW by hand if the TCU is not in the STOW position, if the
system is unpowered and prior to flight. STOW position is considered +90° lookup (to engage the
STOW magnet) and -180° from the flight path.
1.3.4 Turret Functions
Function
Reference Section/Paragraph
Power ON/OFF
1.4.1
Turret Steering Joystick
1.4.2
Change/Cycle Sensors
1.4.4 (systems with TV and IR)
1.4.11 (systems with TV, IR and Spotter)
Set Azimuth Drift
1.4.12
Set Elevation Drift
1.4.13
Cage
1.4.14
Set Cage position
1.4.14
Zero set Joystick offset
1.4.7
STOW position
1.4.14
Set Time & Date
1.4.11
Set Azimuth Joystick Gain
1.4.8
Set Elevation Joystick Gain
1.4.16
Adjust HCU NVG Backlight
1.4.22
Change Elevation Joystick
Sense
1.4.7
Point Mode
1.4.13

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1.3.5 TV Camera Functions
Function
Reference Section/Paragraph
Zoom
1.4.5
Matched Field of Views and
Power Zoom
1.4.5
Auto Focus
1.4.8
Manual Focus
1.4.8
Manual IRIS
1.4.13
Manual Gain
1.4.12
Auto Gain & Iris
1.4.10
IR Cut-off filter
1.4.11
E-Zoom
1.4.6
Image Freeze
1.4.11
1.3.6 Thermal Imager Functions
Function
Reference Section/Paragraph
FOV Change
1.4.5
E-Zoom
1.4.6
Manual Focus
1.4.8
Auto Focus
1.4.8
Auto Span & Level
1.4.10
Image Freeze
1.4.11
Manual Span
1.4.12
Manual Level
1.4.13
NUC
1.4.10
Change Polarity
1.4.9
Digital Detail Enhancement
(DDE)
1.4.11 (see note below)
Changing temperature range
1.4.11
NOTE: When activating the DDE function there may be some rapid blinking in the picture. This is not a fault.
This phenomenon is caused by the sudden fast changing IR levels.
1.3.7 Tracker Functions
Function
Reference Section/Paragraph
Track
1.4.15
Track Mode
1.4.16
Track Gate
1.4.16
Aimpoint Refinement
1.4.2

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1.3.8 Spotter Camera Functions
Function
Reference Section/Paragraph
Zoom
1.4.5
Matched Field of Views and
Power Zoom
1.4.5
Manual Focus
1.4.8
Auto Gain & Iris
1.4.10
Manual Gain
1.4.12
Manual Iris
1.4.13
1.3.9 Laser Range Finder Functions
Function
Reference Section/Paragraph
Power OFF
1.4.17
Power ON (Standby)
1.4.17
Fire
1.4.17
1.3.10 Laser Pointer Functions
Function
Reference Section/Paragraph
Power OFF
1.4.19
Power ON (Standby)
1.4.19
Fire
1.4.19
NOTE: The Laser Pointer is only visible in the Spotter low light Sensor and TV sensor with
IR cut-off filter activated. It is also possible to see the Laser beam with night vision goggles. (NVG)
1.3.11 Laser Illuminator Functions
Function
Reference Section/Paragraph
Power OFF
1.4.20
Power ON (Standby)
1.4.20
Fire
1.4.20
NOTE: The Laser Pointer is only visible in the Spotter low light Sensor and TV sensor with
IR cut-off filter activated. It is also possible to see the Laser beam with night vision goggles. (NVG)
1.3.12 Inertial Navigation System Functions (IMU)
Function
Reference Section/Paragraph
Target Altitude
1.9.3
Geo-Target
1.9.4
Aimpoint Refinement
1.9.6, 1.4.2

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1.4 Controls and functionality
The UltraFORCE 350-HD has been designed for ease of use with all functionality directly
available using hardware controls, eliminating the need to navigate menu selections.
The following section explains the function of all HCU controls. With reference to the
Hand Controller Unit (HCU) switch layout in § 1.14.
NOTE: Please observe that only the camera payload that is currently active/selected,
can be controlled with the HCU.
1.4.1 Power Switch
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
Off
On
Control type:
Lift and latch, two position toggle
switch.
Functionality:
Controls system power.
-
POWER ON
See § 1.3.1 Power-On
POWER OFF
See § 1.3.2 Power-Off

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1.4.2 Thumb Joystick
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
(No legend)
Control type:
X/Y analogue thumb joystick.
Functionality:
Dual function.
-
TURRET
STEERING
AZ & EL
1) In STEER mode the thumb
Joystick provides manual
steering of the TCU line of sight
in azimuth and elevation axis.
The Joystick provides a
maximum movement rate scaled
appropriately for the active
sensor’s current field-of-view.
Text field 1: STEER
Bar Field 15: AZ Indicator
Text Field 15a: ± ##.#o
(Azimuth Angle)
Bar Field 14: EL Indicator
Text Field 14a: ± ##.#o
(Elevation Angle)
AIMPOINT
REFINEMENT
2) When the Auto Tracker or
Geo-Target function is engaged
and tracking, it provides the
following tracker mode
dependent functions;
a) Correlation Tracking –Auto
Tracker aimpoint refinement
b) Centroid Tracking
NOTE: This mode is tracking bounded
objects, and the use of aimpoint
refinement will most likely make the
tracker to lose the target and revert to
COAST mode (See § 1.4.16 and 1.5.1)
c) Scene Lock –
Auto Tracker aimpoint refinement
d) Geo-Target –
Aimpoint refinement
Text field 1: TRACK
Text field 11: CORR
Text field 11: CENTR
Text field 11: SCENE
Text field 1: GEO

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1.4.3 Function Push button
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
(No legend)
Blue Color
FUNC
Control type:
Momentary push button.
Functionality:
The function is dependent on the
activation of a second dial or
button.
-
1.4.4 Change Sensor Push button
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
Ch
Control Type:
Momentary push button.
Function:
Functionality dependent on system
configuration and/or mode as
follows;
-
(2 sensor system)
CHANGE/CYCLE
SENSORS
Momentary push will cause a
cycling between sensors.
[ TVIR(TI)TV ]
Text field 2: TV / -
Text field 2: TI / -
NOTE: Applicable to systems
with TV and IR payload only.
(3 sensor system)
No function
NOTE: Applicable to systems
with TV, IR and Spotter
payloads.
For control/cycling of sensors,
See § 1.4.11
“ENTER”
3) In menu mode;
Confirms a command in menu
mode.
-

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1.4.5 Zoom button
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
W T
Control type:
Rocking centre biased analogue.
(The switch is labelled Tfor telephoto and
Wfor wide)
Function:
Function dependent on selected
sensor as follows;
-
TV
ZOOM
1) TV sensor selected;
TV Zoom control
Pushing “T” causes the TV camera
to zoom towards NFOV.
Pushing “W” causes the TV camera
to zoom towards WFOV.
Text field 3: ###
###= Actual FOV in degrees
TI
FOV
CHANGE
2) TI sensor selected;
TI FOV control
Pushing “T” causes the camera to
switch lens to next narrower FOV.
Pushing “W” causes the camera to
switch lens to next wider FOV.
Text field 3: xFOV
Actual FOV is shown:
x = N, Mor W
N = Narrow
M = Mid
W = Wide
SPOTTER
ZOOM
3) Spotter sensor selected;
Spotter Zoom control
Pushing “T” causes the camera to
zoom towards NFOV
Pushing “W” causes the camera to
zoom towards WFOV.
Text field 3: ###
### = Actual FOV in degrees
When the function “matched field-of-
views” is ON; (See § 1.4.21)
When switching to another sensor
the zoom values automatically sets
to the approximate same FOV.
-

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1.4.6 E-Zoom Push button
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
E
Control Type:
Momentary push button.
Function:
Dual function dependent on selected
sensor as follows;
-
TV
E-ZOOM
1) TV sensor selected;
Momentary push will cause a cycling
between x2 and no E-Zoom of the
current optical zoom.
NOTICE: x4 is also available in some
configurations.
Text field 3: ###x2
(Text field 3: ###x4)
(###is reflecting the current
optical field-of-view)
TI
E-ZOOM
2) TI sensor selected;
Momentary push will cause a cycling
between x2 and no E-Zoom of the
current optical zoom.
Text field 3: #FOVx2
(#FOV is reflecting the current
optical field-of-view)
-
3) Spotter sensor selected;
No function
(No E-Zoom available on Spotter)
-

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1.4.7 Inv/Cal Push button
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
Inv
Cal
Control type:
Momentary push button.
Function:
Dual function.
-
CHANGE
ELEVATION
JOYSTICK
SENSE
1) Toggles and inverts the joystick
elevation sense (direction) to suit
Operator preference.
The Inv button must be pushed and
held down for two (2) seconds
before released.
-
ZERO SET
JOYSTICK
OFFSET
(JOYSTICK
CALIBRATION)
2) Pushing the FUNC and Cal
buttons simultaneously, will zero
set the joystick offset.
-
NOTE: This function will “zero
out”any offset caused by
mechanical deflection in the
joystick.
NOTE: It is a recommended
best practice to perform this
action before a mission is
started.

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1.4.8 Focus Dial
Legend
FUNCTION
Description
Screen Symbology
Reference/Notes
F
Control type:
Continuously rotating encoder with
momentary push button.
Function:
Functionality dependent on selected
sensor as follows;
-
TV
MANUAL
FOCUS
1a) TV sensor selected;
Manual control of TV focus by
rotating the button/dial CW/CCW.
NOTE: If TV is in auto focus mode, any
rotation of the control button causes the
focus to revert to manual mode. The TV
focus will then remain in manual mode until
the Fbutton is pushed.
Text field 5: MF
Text field 6: ->>---INF
(shows actual focus position,
when rotating button)
TV
AUTO
FOCUS
1b) TV sensor selected;
Momentary push causes the TV
camera to switch to “one shot” auto
focus.
Text field 5: AF
TI
MANUAL
FOCUS
2a) TI sensor selected;
Manual control of TI focus by
rotating the button/dial CW/CCW.
NOTE: When TI is in auto focus mode, any
rotation of the control button will cause the
focus to revert to manual mode. The TV
focus will then remain in manual mode until
the Fbutton is pushed again.
Text field 5: MF
Text field 6: ->>---INF
(shows actual focus position,
when rotating button)
TI
AUTO
FOCUS
2b) TI sensor selected;
Momentary push causes the TI
camera to switch to “one shot” auto
focus.
Text field 5: AF

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1.4.8 Focus Dial (continued)
FUNCTION
Description
Screen Symbology
Reference/Notes
SPOTTER
MANUAL
FOCUS
3a) Spotter sensor selected;
Manual control of Spotter focus by
rotating the button/dial CW/CCW.
Text field 5: MF
Text field 6: ->>---INF
(shows actual focus position,
when rotating button)
(SPOTTER
AUTO
FOCUS)
3b) Spotter sensor selected;
No function
(No auto zoom available on Spotter)
Text field 5: MF
SET AZ
JOYSTICK
GAIN
4) TV sensor selected;
(zoomed in more than 50%)
Press and hold FUNC button and
rotate the Focus Dial to set Azimuth
Joystick gain.
-
See § 1.4.16 for setting of the
Elevation gain