mcmurdo C1 S-VDR User manual

C1 S-VDR
Service Manual

Commercial in confidence 36-261
C1 S-VDR service manual Issue 1
Table of Contents
1. Introduction ..........................................................................................................1
1.1 Scope..............................................................................................................1
1.2 Applicability .....................................................................................................1
1.3 Servicin equipment .......................................................................................3
1.4 Safety notices .................................................................................................4
1.5 False alarms ...................................................................................................6
1.6 Deactivatin the EPIRB ..................................................................................6
2. Assessment ..........................................................................................................7
2.1 Maintenance tasks..........................................................................................7
2.2 Routine testin ................................................................................................7
2.3 Assessment ....................................................................................................8
3. Maintenance rocedures ..................................................................................11
3.1 Inspection......................................................................................................11
3.2 Functional tests.............................................................................................12
3.3 Messa e read ...............................................................................................13
3.4 Internal inspection.........................................................................................14
3.5 Disassembly..................................................................................................15
3.6 Reassembly ..................................................................................................20
3.7 Leak testin ...................................................................................................28
3.8 Battery replacement......................................................................................29
3.9 Disposal of batteries .....................................................................................29
3.10 HRU Replacement Kit...................................................................................30
3.11 Pro rammin ................................................................................................34
3.12 Data Recovery ..............................................................................................34
4. Fault finding........................................................................................................36
4.1 Confirmin 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 copyri ht (©) and contains proprietary owned intellectual property ri hts and
confidential data. All ri hts are strictly reserved. The information must not be used except for the a reed 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 a reed purpose is fulfilled.

C1 S-VDR service manual Issue 1 Pa e 1
1. INTRODUCTION
The Simplified Voya e 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 Emer ency Position Indicatin 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 reatly enhances the accuracy of the position
transmitted to the rescue services.
The S-VDR FFC maintains a store of information concernin the position, movement,
physical status, command and control of a vessel over a 12-hour rollin period.
Should any incident occur which requires investi ation, the information contained in
the Capsule can be made available to both the Administration and the ship-owner.
This information may assist durin any subsequent investi ation to identify the
cause(s) of the incident.
The final recordin medium is an ATA FLASH drive system installed in the Capsule.
The Capsule is desi ned to float free automatically if the ship sinks, and to transmit
its current location information throu h the COSPAS-SARSAT satellite network. The
Capsule complies with the requirements of IEC 61996-2.
The Capsule is capable of bein accessed followin an incident but is secure a ainst
tamperin . The Capsule encloses the Data Recordin Unit (DRU) containin the
recordin medium. The final recordin medium is not accessible by standard
operatin procedures durin normal ship operations. Stored information can be
retrieved to an external device via the Data Collection Unit (DCU) without openin 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 throu h 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 emer ency servicin of the S-VDR equipment
listed below.
This manual represents the ori inal equipment manufacturer’s (OEM) service
documentation applicable to these products.
1.2 Applicability
This information applies to the followin 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

C1 S-VDR service manual Issue 1 Pa e 2
S-VDR EPIRB in mount

C1 S-VDR service manual Issue 1 Pa e 3
1.3 Servicing equipment
All a ents are obli ed to possess specialised equipment to ensure that S-VDRs are
serviced correctly. A messa e reader (ARG5410 or equivalent) is mandatory; service
a ents in countries where RF power measurement is required must also have a
suitable RF power meter and attenuators.
Equipment:
Messa e reader (e Sartech 5410)
Pro rammin Kit
PC computer and printer
Static safe work area with operator wrist strap
Ma net
Conductive metal plate or shortin 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 dischar e (ESD)
which can cause immediate or hidden lon term dama e. It is important that the
PCBs are only handled under suitable antistatic conditions.
Ideally, a fully rounded workstation, which has conductive surfaces to avoid the
build up of static char e, should be used.
As a minimum, the operator must be connected to a ood earth point throu h a
resistance of 1Mohm. This is usually achieved by wearin a suitable wrist strap.

C1 S-VDR service manual Issue 1 Pa e 4
1.4 Safety notices
Please read the followin for your safety:
This product has been assessed as presentin ne li ible hazard in a sealed
serviceable state.
Safety analysis
The followin table summarises the nature of the hazard which may be present when
the unit is opened or serviced; each hazard is discussed at reater len th in the
detailed sections.
Hazard cause Hazard identification recautions
Lithium battery Explosive risk, corrosive fumes,
fire, biolo ical hazard
Handle appropriately, avoid
contact
Strobe Bri ht li ht Avoid starin at li ht
Radio frequency
radiation
Physiolo ical hazard Avoid close or prolon ed
exposure
Lithium batteries
Hazardous chemicals Wear loves
The batteries used in these products contain Lithium (Li). Lithium is inflammable,
reacts violently with water and constitutes a biolo ical 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 usin appropriate
safety precautions. The use of rubber loves as a routine precaution is
recommended.
The Lithium batteries contain 21 of Lithium; local and international shippin
re ulations may require certain packa in standards and labellin . Batteries have
special disposal requirements.
In the event of leaka e of the battery electrolyte (which can be reco nised by a
pun ent odour), take care to avoid contact, particularly with open wounds; do not
in est the material. Do not attempt to dischar e a leakin battery – remove it usin
appropriate handlin materials and seal in a plastic ba , then dispose of it throu h an
approved environmental disposal a ent, or in accordance with local re ulations.

C1 S-VDR service manual Issue 1 Pa e 5
Strobe radiation
The LED strobe li ht fitted to the EPIRB section produces intense flashes of li ht. No
dama e is likely to be caused by intermittent exposure, but prolon ed 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, I A)
Observe all safety precautions relevant to the country of operation. As a eneral rule,
protective overalls, loves and o les should be worn when handlin these
chemical a ents, but different countries may have additional requirements which
must be observed.
Ensure that all chemical a ents are handled in accordance with the manufacturer's
instructions, and that suitable protective clothin is worn.
Make sure that the workin area is well ventilated, and that chemical substances are
not left exposed. Observe ood hy iene practices; do not eat, drink or smoke when
handlin chemicals.
Cyanoacrylate adhesives bond instantly on contact. If skin is bonded, it can usually
be released by a gentle peelin action; above all, do not panic and avoid direct
pullin on bonded skin.
Read the manufacturer's instructions before usin any chemical a ent.
Wear o les Wear overalls Wash hands Wear loves

C1 S-VDR service manual Issue 1 Pa e 6
1.5 False alarms
Every care must be taken to avoid the eneration of false alarms.
The S-VDR has a sea switch; it is not uncommon for these to activate in rou h seas
or heavy rain because the S-VDR is badly fitted in its mountin bracket. The
mountin bracket incorporates a ma net to disable the S-VDR. If the S-VDR is
wron ly fitted the cutout is not actuated by the ma net, 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 enerated. 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 coast uard 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 ive the unique ID.
1.6 Deactivating the E IRB
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 flashin within one minute.
If the FFC continues to transmit, it may have a fault. The next sta e is to attempt to
deactivate the unit by a ma net. For this purpose the FFC may be fitted to its mount,
or a suitable ma net may be placed a ainst the case alon side the reed switch. See
pa e 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 si nals
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 re arded as a last resort as 10 screws have to be removed and further
internal dama e may occur. If this has to be done, once the FFC is open then
disconnectin the battery lead stops all activity. See section 3.5.
.

C1 S-VDR service manual Issue 1 Pa e 7
2. ASSESSMENT
2.1 Maintenance tasks
Servicin a ents (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 ood common practice is observed.
False alarms caused by inadvertent activation must be avoided
The functions which can be performed by SBM providers are:
• Routine testin
• Repro rammin
• Messa e readin and verification
• Power measurement
• Battery replacement
• Leak testin
• HRU replacement
• Data recovery
• Fault dia nosis 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 dama e.
In accordance with IMO uidelines (Circ 1040) an EPIRB fitted to a GMDSS
compliant vessel is recommended to under o a yearly on board inspection.
In accordance with IMO uidelines (Circ 1039) an EPIRB fitted to a GMDSS
compliant vessel is recommended to under o a five yearly SBM inspection.
Whatever the reason for the return of an EPIRB to a shore-based maintenance
a ent, the EPIRB must be subjected to a full assessment before any other action is
taken. The a ent has a responsibility to ensure the EPIRB is completely serviceable
and is fit for its purpose.

C1 S-VDR service manual Issue 1 Pa e 8
2.3 Assessment
Every S-VDR returned for servicin , of whatever nature, must be fully assessed to
determine its operational status. The dia ram shows the tasks which must be carried
out for each servicin situation.
If the FFC is opened for any reason, it must be fitted with a new sealin kit (the
asket is not re-usable). It must then be subjected to a leak test.
Assessment form
The assessment form, shown on the next pa e, is an essential tool in performin
dia nosis. It may be used to support customer billin , 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 chan e
should be recommended to the customer.
Openin the FFC for internal inspection is only required if a problem is found.
RECEI T
Assessment
Inspect
Functional test
Message read
Functional test
Messa e read
Pro ram
Print forms
Complete labels
Fit HRU
Mark dates
RETURN
HRU change Reprogram
Disassemble
Internal inspection
Fault find
Repair
Disassemble
Internal inspection
Fit battery
Mark dates
Reassemble
Leak test
Fault found
Battery
change

C1 S-VDR service manual Issue 1 Pa e 9
S-VDR ASSESSMENT Ref No Date
Customer Vessel
Type Man. Serial No Battery
expiry date
Country Call si n/MMSI
UIN Cate ory Auto/Manual
MMSI 
Call si n 
Serial 
Customer comments
Warranty claim YES/NO
INS ECTION Auto bracket FFC
HRU date
Ma net present 
Strap/buckle intact 
Plastic condition 
Cables OK 
BIM 
Inte rity seal intact 
Plastic OK 
Antenna OK 
Lanyard OK 
Comments
FUNCTIONAL TEST
Sea Switch
Activates 
Deactivates 
Does not activate with ma net 
Self test
Red LED on 
3 strobe flashes  Green
LED 
Live mode
Strobe activates 
within 8 s
Comments
MESSAGE READ ID
121 sweep heard  Country
MMSI/Call si n/Serial no
406 frequency OK  Man Serial No EPIRB No Auto/Man
Comments
INTERNAL INS ECTION Required 
Water in ress  PCB corrosion  PCB fault  Battery volta e
Plastic dama e  Switch fault  volts
Comments
Conclusions
Assessed by Si ned Date FINAL LEAK TEST
New arts
HRU kit 
Battery kit 
Top cone kit 
EPIRB PCB 
Lanyard 
Sealin Kit 
DSM 
Other:
Pass/Fail

C1 S-VDR service manual Issue 1 Pa e 10

C1 S-VDR service manual Issue 1 Pa e 11
3. MAINTENANCE ROCEDURES
3.1 Inspection
Release mount inspection
1. Check the strap for correct tension. Hold the FFC in its mount, locate the HRU
in its holdin lu s 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 dan er that the FCC could be fixed with
the locatin lu not en a ed.
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 cleanin , 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 dama e, readability and
adhesion.
7. Remove the screw retainin the mount bracket and inspect the BIM.
BIM Inspection
The BIM outer case should be in ood condition – there should be no visible dama e
or rustin . Remove the top cover and inspect the lands – these should be ti ht.
Ti hten to 300cNm+/-25cNm usin a 19mm torque driver if required.
FFC inspection
1. Examine both cones for si ns of crackin or fracture that mi ht lead to water
in ress. Look in particular around the switches and the 10 bolt mountin holes
as these are under the most stress. Also look for splatters of paint on the
cones as the solvent within the paint mi ht 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 housin , then the FFC has leaked and must be serviced. Also inspect
the top of the circuit board throu h 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 dama e.
6. Check the labels fitted to the FFC for readability and adhesion.
7. Ensure the inte rity seal is intact. This is essential to uarantee that the
battery has not been dischar ed.
8. Examine the sea switch contacts on the bottom cone. If there are si ns of rust,
white powdery corrosion or salt deposits then the contacts must be cleaned.

C1 S-VDR service manual Issue 1 Pa e 12
3.2 Functional tests
The tests detailed in this section confirm that the FFC is fully functional.
Equipment Required
Special screened/anechoic chamber As required
Messa e Reader Sartech 5410 or equivalent
Ma net 82-209 or similar
Conductive plate/shortin link 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
usin a link wire. Within approx 8 seconds the FFC must activate (start to
flash).
2. Immediately place the ma net in the position shown.
Add picture
The FFC must deactivate (stop flashin ) immediately. Remove the ma net
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. Press and hold the TEST button.
2. The red LED should immediately li ht indicatin self test is runnin .
3. On successful completion of the self test sequence the reen LED will
flash 3 times and the strobe will flash 3 times.
4. Release the TEST button
CAUTION: Do not subject more than one FFC to self test at any time, as two units
may interfere durin 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 prolon ed, a screened enclosure must be used. The inte rity seal will be broken
durin 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 inte rity seal.

C1 S-VDR service manual Issue 1 Pa e 13
3.3 Message read
Part of the IMO requirement is that the SBM provider verifies the messa e. This can
be done with a "Messa e 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. On the Reader select RECV mode
2. Position the Reader approx. 1m (3 feet) from the FFC
3. Perform a self test on the FFC
4. After about 12 seconds the 121.5MHz detector should emit three bursts of
sound
This proves the 121.5MHz homer is radiatin and modulatin correctly.
5. The Reader should beep and report S’TEST OK
6. The Reader will revert to its Menu. Select VIEW mode
7. Use ← → keys to view the decoded 406MHz messa e content
8. Confirm the frequency was within 406.020 – 406.030
This proves the 406MHz transmitter is radiatin within the correct frequency band. If
the ARG5410 Reader is not used, then another facility for measurin the 406MHz
frequency must be provided (a spectrum analyser for example).
9. Confirm the 15 di it ID a rees with FFC identity label UIN
This proves the 406MHz transmitter is modulatin correctly and the EPIRB is
pro rammed with the correct vessel identity. If the ARG5410 is not used then another
facility for messa e decodin must be provided (other messa e readers).
10. Confirm the Fla state and the Serial No / MMSI / Callsi n a rees
Typical screen Q
11:25
Mesg#11 S’TEST OK
ID: 9D0D071D3B00013
406.0257 MHz ASS
Common problems
Audio tone If not heard then reduce ran e 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 messa e 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 messa e 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 messa e are FF FE 2F… instead of the FF FE D0… for self test mode.

C1 S-VDR service manual Issue 1 Pa e 14
3.4 Internal inspection
Internal inspection is important both for dia nosin faults and for detectin possible
faults early. Internal inspection is required under the followin conditions:
• A fault has been observed and needs to be dia nosed
• If there is any indication of water inside the FFC
• Any salt deposit or corrosion is visible inside
• Si ns of any crackin 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 usin the notes below as uidance on what to
look for durin the disassembly process.
rior to opening E IRB
• Carry out inspection as per section 3.1
With dome and gasket removed
• If there is a pun ent smell, then suspect that the Lithium battery pack has leaked.
See section 1.4 for advice. Wear rubber loves. Dama ed lithium batteries may
be unstable and pose a serious safety hazard. Leaka e usually dama es circuit
boards, so it is often necessary to scrap the EPIRB without further investi ation.
• Check top of circuit board for white salt deposits, dull rey corrosion or wetness.
If any corrosion is evident the FFC should be completely disassembled.
• Check plastic parts, especially screw positions, for si ns of crackin and for
possible leaka e paths.

C1 S-VDR service manual Issue 1 Pa e 15
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 ently 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 dama e. Use
an 11mm A/F socket to loosen the TEST switch boot. A sli ht hiss will be
heard as the vacuum releases. When it stops, re-ti hten the TEST switch
boot. Pull the cones apart.
3. Gently lift the top cone up takin reat care not to dama e the Reed switch
PCB which extends into the DSM

C1 S-VDR service manual Issue 1 Pa e 16
4. . The battery and sea switch leads will limit the cone separation; unplu them
as shown and feed them back throu h the DSM.
5. Remove the lar e rubber askets (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 CB section
Observe anti-static precautions. Unplu the two switches ON and TEST.
Remove the seven board mountin screws and withdraw the board, complete
with antenna from the top cone. Take care not to loose the foam pads locatin
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 CBs
The PCBs are joined by the electrical connectors (push fit) and the wed e.
The wed e is very ti ht 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 undoin the switch boot usin an 11mm
driver. The switches are located in the plastic and cannot rotate.